Industrial Automation Magazine India

IT-OT Convergence in Smart Manufacturing

Published on : Monday 20-01-2020

IT/OT convergence is a key aspect in building a digital manufacturing transformation by integrating operational technologies, says Titli Chatterjee.

Manufacturing is a complex ecosystem and has gone various phases of development over the period. With the world experiencing revolution of technology, emerging technologies like Internet of Things (IoT), artificial intelligence (AI) and machine learning (ML) have provided a smarter, efficient and more productive generation. The ongoing fourth industrial revolution (Industry 4.0) will impact manufacturing at global level, spawning the developing and emerging countries as well. However, the biggest obstacle for most manufacturers at this juncture is maintaining the right balance between information technology (IT) and operational technology (OT). To outpace the potential disruptions and maximise operational efficiency, convergence of IT and OT will soon gain momentum in the manufacturing sector.

Collaborations have always been operative, thus a corrective approach of the two groups would help companies attain the vision of “factory of future”. 

Both groups of Information Technology and Operational Technology will drive impacts, hence the convergence of IT and OT. Few of the proceeds through IT/OT would be:
 

• Upskilling – This shift will bring new and challenging projects to the IT and operations professionals working within the industry
• Monetising Outcomes – Improving operational efficiency and maximising profitability
• Value Creation – Real-time operational data that can create additional value for the companies and industries
• Digital Transformation – An agendum of the digital transformation roadmap would be inclusion of IT/OT easing the process of pull-based replenishment and addressing other methods related to digital transformation initiatives
• Faster Turnaround – The IT/OT integration will eliminate unplanned downtimes through predictive maintenance, and
• Data Privacy – Connected devices will have gamut of data and data security is mission critical for manufacturing. IT/OT must work together, enabling secure data flow.

Thus, IT/OT convergence is a key aspect in building a digital manufacturing transformation by integrating operational technologies such as SCADA, programmable logic controllers, meters and sensors which work in real-time with IT systems. The convergence is a cryptic word, however in this context it means building a common platform between departments or groups such that they are interdependent on one another and rely within an organisation in terms of expertise.

The Driving Factor behind the Convergence
Though there are multiple aspects such as increasing complexity of networking, huge pool of data and the need for an increase in process maturity, the people factor tops the index. The most significant facet of the convergence is the collaboration of the IT and OT people working together to solve combinatorial problems. In the convergence of IT and OT, each has a value to offer. Manufacturing, building and process controls, communications, etc., had begun right from the first industrial revolution, however the challenge was and continues to be, the understanding of physical systems and partnership with IT. Enterprises are adopting technologies that affect every aspect of the operations, hence every employee across the hierarchy is an active participant of digital transformations in an organisation. The same goes while mitigating risks and data threats in the integration of IT/OT where the people factor plays a substantial role in devising and executing convergence strategies.

Convergence in the Real World – Bentley Systems Story
Digital engineering models are driving a convergence between operational and information technology. A relevant example would be on how South Australia Water is currently using predictive and real-time operational analytics to forecast water demand and improve customer service, while reducing operational costs. 

Objective – To create a demand forecasting tool, real-time information on operational and IT sides of the organisation were sourced. Bentley’s predictive analytics software enabled the process of sourcing real-time data, calculations and analysis along with visualisation capabilities. This operational intelligence platform helped in monitoring real-time sensor data from reservoirs, water treatment plants, valves, flowmeters and pumps, combining with climate changes, energy, cost and population to display on dedicated dashboards. This enhanced understanding inter-relationships and better decision making with more accurate predictions and insights.

Mazak-Cisco Story

Mazak, a Japanese machine tool builder required a common, standards-based method to securely connect and derive value from the unstructured raw data in its machine tools. In addition, it needed an advanced security system suitable for IT and OT. This application needed to run on the network infrastructure on the factory floor with real-time data availability on process, overall equipment effectiveness (OEE) and sensor data. Mazak implemented Internet of Things connectivity – Cisco Industrial Ethernet 4000 Switch and real-time analytics – Cisco Connected Streaming Analytics. This helped in cost consolidation through running real-time analytics on IoT network infrastructure and rapid time to value with measurable customer impact.

The India Scenario
Research indicates the GDP growth from the manufacturing sector in 2018 has been 4.6 per cent. The sector in India is expected to contribute 25 per cent to the GDP in 2025. The Make in India initiative is paving way for India to become the next hub for hi-tech manufacturing with global giants such as GE, Siemens, HTC, Toshiba and Boeing are in process of setting up manufacturing plants in India impacted by India’s market of more than a billion consumers and increasing purchasing power. Also, proportion of additional smart factories in India in the next five years would also witness a step-up. However, the adoption rate shows a dip posing significant challenges such as IT-OT Convergence and lack of digital skills. To strengthen the competitiveness in the global economy, activating sustainable manufacturing, realise operational efficiency and profitability organisations in the manufacturing sector should include the integration of IT and OT including digital platforms deployment, data readiness and cybersecurity as part of enterprise strategy. Nonetheless, with changing times enterprises are preparing for transition to converging and aligning of IT and OT environments.

Moving Smart Manufacturing Forward 
There is no single way to win the race, it is a gradual process requiring diverse skill sets to execute pre-defined strategies. One clear precursor for enterprises would be to coordinate IT and OT to implement a centralised management across the value chain comprising of certain factors such as security, governance models, and operational processes. A new set of leaders would emerge who will dedicate themselves to overcoming the disparity of IT and OT, organisations or the laggards who do not will have to redraft the agenda because the long-term benefits of IT-OT convergence would be worth the effort. In the Factory of the Future, IT/OT planning would ideally be the crux as both the groups will be unlocking new opportunities for the manufacturing sector. Operational technology can no longer be an independent group, while IT can’t impose standards and procedures that don’t work in an OT environment.

Titli Chatterjee has been leading the ER&D/Industry 4.0 research initiatives of NASSCOM, having experience in research and consulting in the areas of emerging technologies and engineering services. In her current role as Manager – Research Titli is closely working with industry leaders, startups and other stakeholders to highlight how technology can be a game changer on the industrial front, and developing a roadmap in disruptive technologies for Indian IT-BPM industry.