A key issue in IT/OT convergence is that operational technology assets often lack the structured management frameworks used in IT, resulting in fragmented asset oversight, inconsistent lifecycle tracking and increased risk across the enterprise. In addition, manufacturers have a growing need for hybrid skill sets and cross-functional roles, and many are concerned about retaining institutional knowledge as senior workers retire.

Legacy OT systems and lack of network visibility are also key challenges. While OT environments need stronger security, tools and solutions designed for IT may not readily translate. Unifying security across the organization can be complex, especially if an environment requires extensive customization. Data is another common issue; while IIoT assets generate valuable data, manufacturers need technical integration and strong governance to leverage this telemetry for improved decision-making. Finally, manufacturers face challenges related to supply chains, workforce shortages and sustainability mandates.

As IT/OT convergence matures, companies can better leverage advanced capabilities to refine their operations in ways that address these challenges.

CULTURE AND MINDSET: A good starting point to bring IT and OT teams together is to ensure that each understands the other’s goals. While their goals differ in important ways, they tend to become more aligned as manufacturers’ smart factory capabilities mature. For instance, OT teams may perceive cybersecurity measures as an impediment to quality control and productivity goals. As systems converge, however, the visibility and monitoring solutions that protect IT also ensure uptime and proactive troubleshooting for OT. Even so, leaders should recognize that teams may need to shift their mindset and behavior; for example, a unified security strategy that requires adherence to established standards and protocols should also prevent the use of ad hoc solutions that result in shadow IT.

SYSTEMS INTEGRATION: Integrating OT and IT systems is complex, especially when outdated infrastructure is involved. Interoperability issues often arise with systems that were originally created to serve distinct purposes and priorities. The technologies behind these systems are inherently different, making it challenging for them to work seamlessly together. For example, OT systems are designed to run production 24/7, whereas IT systems prioritize resilience and data protection, even when that requires planned downtime. Another common challenge is that programmable logic controllers in some instances can be classified as both a client and a switch if running Device Level Ring redundancy protocols; or, they may use protocols that IT systems don’t readily support, such as Honeywell Smart Distributed System, requiring custom interfaces or other solutions. Similarly, legacy manufacturing equipment may have vendor-specific features and functionalities that don’t play well with modern IT infrastructure.

CDW combines technology expertise and manufacturing experience to help companies facilitate IT/OT connections that increase business agility and accelerate operational efficiency.

TRANSFORMATION WORKSHOP: CDW’s Transformation Workshop helps manufacturers create a strategy for developing smart factories, with outcomes such as real-time production monitoring, proactive maintenance, robust cybersecurity and cost optimization. Modern infrastructure and well-integrated systems support data-driven insights and the use of AI and automation to optimize operations in key areas, including asset management and inventory planning. From using sensor data to identify wasteful and inefficient processes to applying predictive analytics to reduce equipment breakdowns, smart factories drive across-the-board improvements that help manufacturers stay profitable and competitive. This workshop helps manufacturers assess their needs, provides custom recommendations and supports a clear, strategic roadmap toward IT/OT convergence.

OT NETWORKING ASSESSMENT: In the modern factory environment, secure networking is crucial. CDW’s OT Networking Assessment helps manufacturers identify and address network vulnerabilities that could lead to a breach. For example, while IIoT devices have accelerated digital transformation, they have also increased the attack surface, so it is critical to ensure they are properly protected. OT networks, however, especially those running on legacy infrastructure, may be unable to support the capabilities that keep networks safe, such as centralized visibility, asset discovery and segmentation. CDW’s experts can help manufacturers assess their networks holistically, taking into consideration the unique needs of manufacturing environments and the challenges that can arise when bringing OT and IT networks together.

IT/OT MATURITY ASSESSMENT: CDW now offers an IT/OT Convergence Maturity Assessment designed to provide clarity about manufacturers’ smart factory readiness and recommendations for moving forward. CDW’s experts evaluate current technologies, IT/OT governance, process alignment (asset, change, incident, code, release management), technology alignment, data management and — last, but not least — security and compliance.