Automation tools Coupling OT and IT: Achieving connectivity together

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To achieve goals such as efficiency, flexibility and sustainability, companies need to align operational and information technology (OT and IT) as best as possible. With automation tools that link IT and OT, manufacturing companies can meet this challenge. A cooperation of Dassault Systèmes, Omron and Nokia illustrates what this can look like in practice.

Economic uncertainty, a lack of skilled workers, new products, and climate neutrality: Companies currently face a mountain of challenges that can only be addressed with a strategically sound digitalization strategy. In a Deloitte study from 2019, 86 percent of surveyed executives in the manufacturing industry stated that smart factory solutions would be key factors for their competitiveness over the next five years. But the more interest in digital tools grows, the more apparent it becomes that OT (Operational Technology) and IT (Information Technology) often diverge greatly. In order for today's visions of a manufacturing future to become reality, these two worlds must be brought together more strategically.

Misunderstandings in terminology

More and more experts are advocating for a convergence of IT and OT. However, anyone considering such a move should first deal with a few misunderstandings about terminology: IT, OT, and IoT (Internet of Things) may seem similar at first glance, but they have very different meanings. While operational technology, i.e., hardware and software for controlling industrial equipment, focuses on the behavior and results of machines, IT refers to information and communication. OT includes the systems that form an interface to the real world, including controls, actuators, and sensors. IT, on the other hand, includes computers, data storage, network infrastructure, software, and processes used to produce electronic data. OT monitors events, processes, and physical devices, generating information that is then processed by IT systems. The IoT is the data flow between these two worlds—without data, no IoT.

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Achieving IT-OT Connectivity Together

In industrial automation, OT and IT have always been considered two separate worlds. Companies either focus on one area or the other, as both spheres cannot be comprehensively successfully covered by a single player. However, such a one-dimensional and isolated approach is problematic, as both IT and OT can only fully realize their potential with well-thought-out IT-OT connectivity. This realization is driving the development of ecosystems. Companies from various fields are forming cooperations to realize new solutions at a higher level and bring integrated IT-OT solutions to the market.

Omron, Dassault Systèmes, and Nokia are working together

An example of this synergistic approach to intelligent automation is the partnership between Omron, Dassault Systèmes, and Nokia. In this cooperation, Dassault contributes the IT element (virtual twinning), Omron its OT expertise (industrial automation), and Nokia its 5G mobile technology. The result is an ecosystem that can adapt to various applications and markets. Further partners with know-how in areas such as system integration, robotics, and mechanical engineering also contribute to this. The ecosystem model is a fast and flexible alternative to acquiring own IT-OT capabilities through business acquisitions, training, or similar. Nokia's 5G mobile networks support high-speed communication between machines, people, and systems, Dassault Systèmes' virtual twin functions enable real-time monitoring and optimization, and Omron brings new solutions to life through intelligent, integrated, and interactive automation. The combined knowledge can be incorporated into the development of IoT-based automation solutions for the automotive, FMCG, pharmaceutical, and medical technology industries. Automation, high-speed connectivity, and digital twin technology bring measurable benefits.

Why is optimized IT-OT connectivity so important?

This can be demonstrated using the example of industrial automation. While an IT provider can create a virtual twin of a production site, a system, or a production line, they often lack knowledge about the processes and behavior of facilities in the real world. So when the virtual twin is altered to optimize a process, the IT specialist does not know whether this is feasible in the real production environment. Here, the OT provider creates added value by providing the twin with data that allows understanding of how the system will behave in the real environment. In this way, IT and OT bundle experiences and insights so that both sides benefit. This in turn results in various improvements, such as faster market introduction of a new product or more efficient use of labor and resources.

Continuous monitoring leads to constant improvements

It is not about a one-time simulation of a process or machine. The virtual twin reflects the physical system in real-time and can be operated during the entire lifespan of a system or product, so it is always possible to test in a safe parallel digital environment how new materials, new components, or new tools will behave. The continuous control of a machine or workflow can also be used for preventive maintenance or energy management.

SCADA and Edge Control improve overview

IT-OT connectivity can support various industries such as manufacturing, electromobility or intralogistics. Virtual models of a new machine or plant help minimize project risks and drastically reduce the time required for building or testing a plant, as costly mistakes are made in the virtual world rather than in the real world. This is advantageous for all manufacturing sectors, but especially for the automation industry, where the launch of new products is being increasingly accelerated and errors are to be eliminated. Also, Scada systems (IT) provide IT-OT convergence by helping to visualize the activity in the production line through the capture of real-time data via a connection to OT line elements. Edge Control (OT), on the other hand, enables swift feedback for precise process adjustments.

Partnerships bring future security

Interactive, integrated, autonomous, and intelligent automation solutions contribute to changing manufacturing, increasing efficiency and productivity, and acting more sustainably. However, companies looking to extract the most from such approaches will need to ensure in the future that automation tools seamlessly integrate IT and OT. Partnerships and ecosystems provide valuable support in this respect and help realize flexible and future-proof manufacturing processes.

This article originally appeared on our sister portal 'MM MaschinenMarkt' (German Edition), Vogel Communications Group .