Today’s businesses operating in industrial environments straddle two worlds: one is operational technology (OT), and the other, quickly expanding, is informational technology (IT). Up until recently, these areas were kept completely separate, sharing little information and manned by employees with largely different skill sets.
Now, however, the two worlds are colliding. IT and OT convergence is the merging of the two, made possible by the development of new technologies such as the Internet of Things (IoT). While this integration brings many benefits, it does pose security challenges, particularly in the architecture of the systems involved.
Let’s explore both informational and operational technology in more detail, as well as how they can be converged, and why they should be. We’ll also look at how to ensure you implement IT/OT convergence securely, and why doing this is a strategic enabler.
What is OT?
OT is simply the control and management of physical devices operating in the real world. This is something that industry has relied on since its earliest days.
To put this in more detail, OT is the combination of hardware and software used to oversee equipment and processes. These days, this involves the use of technologies such as industrial control systems (ICS) and Supervisory Control and Data Acquisition (SCADA) to manage industrial activities in real time.
How is this useful? It offers almost instantaneous feedback that helps you make processes more efficient and dependable, such as reducing downtime or increasing output.
The thing to remember is that OT operates in a tangible environment and involves direct engagement with industrial machinery or processes, such as controlling factory assembling lines or packaging systems.
What Is The Difference Between IT and OT?
You may be more familiar with the term IT. This is the management and processing of data on computers and servers, or any other device that stores information.
The differences between this and OT begin with the environments in which they operate. As mentioned, OT is used in tangible industrial settings to ensure physical systems meet operational requirements. In contrast, IT functions across the broader corporate environment and focuses on supporting virtual data-related tasks, supporting functions like communications and information management.
Another difference is in their approach to security. It’s a primary concern in IT, which heavily prioritises data confidentiality. OT, on the other hand, leans more towards safety and the efficiency or availability of equipment. As a result, system maintenance and updates, which are essential for security, are frequent in IT, while OT minimises them to avoid operational disruptions.
Finally, IT systems are highly connected and are designed to allow data to be shared easily across multiple networks. They handle many types of data in doing this. OT, on the other hand, has traditionally been more isolated and only focuses on certain real-time data, which allows the monitoring and control of equipment.
IT vs OT
| IT | OT |
| Data management focus | Equipment and process control focus |
| Intangible computing environments | Physical industrial environments |
| Data confidentiality | Equipment availability |
| Regular system updates | Infrequent system maintenance |
| Inherently connected | Traditionally isolated |
IT and OT Convergence
IT/OT convergence marries these two domains and breaks down the barriers between them.
The idea of technological convergence like this isn’t new. In many cases, businesses aim to integrate separate systems into a single cohesive one to improve efficiency, cut costs, reduce errors, and gain other competitive advantages.
With the convergence of IT and OT, operational technology in your physical machines can provide vital real-time information (such as equipment status, production rates, etc) to your IT systems. With this seamless flow of data between the digital and physical worlds, IT can not only visualise but also influence your physical operating systems. It monitors and analyses OT data, then feeds insights such as planned maintenance and performance recommendations back to your physical systems, which react to optimise operation.
How Does the Internet of Things (IoT) Enable IT/OT Convergence?
Clearly, the convergence of IT and OT is advantageous to pursue, but how does it happen? This is all thanks to digital transformation and the emergence of new technologies like IoT.
IoT devices are networked computing devices that can collect, transfer, and analyse data. They act as the vital missing link between IT and OT.
Traditional OT devices, like sensors, are designed to collect operational data but typically operate within isolated networks and have limited processing or analytics capabilities. Enter IoT. This data can now be passed on to an IoT hub or platform, which then forwards it to IT systems for analysis and decision-making.
While this has many advantages, it’s important to remember that this direct data link also introduces risk, as a cyberattack on IT systems can potentially impact OT operations, leading to significant financial and operational consequences.
IT/OT Convergence and Security
The concept of converging IT and OT can sometimes raise some eyebrows for those concerned with security. This is because, in the past, the two have been deliberately kept separate in a process known as air gapping.
Air gapping is a security practice where OT systems are intentionally kept physically and logically isolated from IT networks. Why? The reasoning was that this prevented cyberattacks from affecting critical machinery and also helped prevent remote interference. For many years, this was seen as the safest option.
Sounds great, but the reality is that air gaps are more of a limitation than a protection due to many reasons, including:
- OT data is trapped and can’t be analysed by IT systems
- Manual data transfers introduce hidden security risks
- Remote monitoring, predictive maintenance, and automation become impossible
- Modern threats don’t always respect physical separation
It got to the point where many businesses were using manual workarounds to bypass air gaps, which were a lot less secure than controlled digital connections.
The truth is, IT/OT integration introduces real security challenges, including:
- Lack of collaboration: IT and OT teams have traditionally operated separately, so bringing them together increases the risk of oversights and vulnerabilities
- Legacy OT systems: Older machines often lack modern security features and can’t always be upgraded
- Mission-critical demands: OT systems often can’t be paused for necessary IT updates, creating unavoidable security gaps
- High impact of disruption: Any failure in communication or control can have serious operational consequences
The good news is that it is possible to converge IT and OT using devices such as IoT, while also maintaining full confidence in your security and compliance! By combining hardware-enforced security, intelligent data filtering, and deep protocol inspection (as found in 4Secure’s IT/OT Secure Connection), you can ensure that only authorised, sanitised data can flow between environments.
IT/OT Convergence Benefits
Demand across various industries is increasing rapidly, as consumer expectations rise. To meet these new requirements, the only way is to ramp up efficiency and innovation. The words easier said than done come to mind.
But with the introduction of OT and IT convergence, aligning data analytics with core operational processes, it really is possible to achieve significant measurable improvements, such as:
Enhanced Operational Efficiency and Cost Reduction
Crucially, the merging of these two domains introduces real-time data analytics and monitoring of your physical equipment. This means you have a new level of visibility into your operations and can use timely insights to improve efficiency.
The new information also helps you identify areas to optimise resource allocation or enable predictive maintenance, which can greatly cut costs.
Improved Decision Making
If there’s one thing continuous access to comprehensive, real-time information affords you, it’s clarity. And clarity allows you to make confident, informed decisions.
By combining information from the factory floor and your IT systems, you get a fully end-to-end view of performance, so you no longer have to rely on assumptions or delayed reports. Instead, you can make proactive adjustments that align operations with market demands and your organisational goals through effective data exchange strategies.
Better Cybersecurity and Compliance
As mentioned, security can be a challenge in IT/OT convergence, or at least has been seen as one in the past. With the right unified security solution, however, such as 4Secure, you can achieve stronger protection than when defending two disparate systems.
What’s more, by centralising your data management, it’s far easier to ensure consistent regulatory adherence and improve visibility for audits.
Greater Innovation and Competitiveness
Where IT and OT are integrated, innovation often blooms, leading to enhanced manufacturing and industrial capabilities. The reason? Access to a wide range of in-depth data insights brings to light new opportunities and sparks ideas for novel solutions. Follow these prospects, and you’ll soon gain a competitive edge and even break into new markets.
Stronger Company Culture
It may be an overlooked advantage, but bringing IT and OT together also unifies these previously separate teams. It encourages closer collaboration and the sharing of expertise. By breaking down these silos, you achieve a more cohesive effort towards shared goals and a more agile, innovative culture in general.
Automation and Faster Time to Market
When you bring your IT and OT domains together, decisions that once relied on people can now happen system-to-system, with IT automatically triggering actions that enhance production.
Because of this connectivity, feedback loops are far shorter and adjustments can be made near-instantaneously, requiring fewer handoffs between departments. Ultimately, this means products get off the production line and out into the market far faster.
Challenges of IT and OT Convergence
We’ve covered the potential security hurdles to cross when converging informational and operational technologies, but are there any other challenges to face? Honestly, the answer is yes, but it’s nothing that can’t be overcome when taking the right approach to convergence.
Here are a few things to be prepared for:
Integration Complexity
At first glance, OT and IT systems can seem completely different and potentially incompatible — like trying to fit a square peg into a round hole. OT focuses on safety and continuous operation, while IT focuses on flexibility, data access, and rapid updates.
While you do have to carefully align these different priorities and protocols, this is entirely possible with close coordination between teams and the right integration technologies.
Skill Gaps
Because IT and OT teams have previously worked in separate silos, they will likely have gaps in their knowledge when it comes to the opposing domain. This could cause challenges when merging teams, as not everyone will have the skills needed to manage a converged system.
Education is the resolution here. With the right training, your personnel can patch any holes in their existing abilities and gain a deep understanding of both environments.
Interoperability Issues
To keep convergence cost-effective, you should aim to modernise existing OT with information technology, not replace it altogether. But this can pose hurdles, especially since legacy systems may not support modern tech and often have conflicting protocols or data formats.
With the right planning and tools, however, such as using IOT gateways to bridge the gaps, you can achieve effortless communication between the two.
Organisational Resistance
Bringing together two teams like IT and OT requires a shift in organisational culture, which may not always be met with cheer — unless you approach it in the right way. Of course, restructuring departments takes work, which can be frustrating for personnel whose daily processes are disrupted.
Given enough forewarning and a clear strategy, however, the transition doesn’t have to be turbulent. Ensure all teams are aware of the benefits the move will bring, and it’s possible to garner enthusiasm rather than resistance.
Industries That Should Embrace Secure IT/OT Convergence
Manufacturing
Integrating IT into manufacturing equipment aids in predictive maintenance, which reduces downtime and ensures optimal utilisation of machinery. That, in turn, leads to cost-effective and streamlined operations.
Cyber-attacks, particularly ransomware, pose a significant and escalating threat to manufacturing operations. They have been the reason for the shutdown of numerous manufacturing sites annually or even the impairment of safety systems. Therefore, security is essential when making the move.
Power
Power companies benefit from remote access to operational data enabled by IT integration, as it contributes to optimal resource allocation and improved service delivery. This must be implemented with a security-first approach to prevent cyber attackers seeking to disrupt national infrastructure or exploit vulnerabilities for geopolitical or financial gain.
Rail
In the transportation sector, the convergence of IT and OT is crucial for improving asset management. Real-time data supports maintenance, route optimisation, and long-term planning. The added visibility also ensures timely repairs and replacements, bolstering safety and operational efficiency.
Cyber attacks targeting rail systems can cause service disruptions and, more alarmingly, catastrophic events like derailments or equipment damage, so it’s essential to converge IT and OT securely.
Commercial
For commercial organisations, IT/OT convergence improves efficiency and resilience. As cyber threats grow more sophisticated, a breach can disrupt operations and cause serious financial and reputational damage. Secure IT/OT convergence enables regulatory compliance and operational resilience, turning cybersecurity into a strategic advantage rather than just a safeguard.
What Are Best Practices When Converging IT and OT?
So, what’s the most effective strategy for OT/IT convergence to avoid the challenges above? No matter what industry you’re in or OT environments you use, the following best practices will help guarantee a successful transition:
Communication
As in any business venture, or pretty much any situation in general, communication is key. Firstly, you need to be clear about your goals for convergence so that both IT and OT teams, and all stakeholders, understand the objectives and agree they’re realistic.
This clarity ensures everyone is aligned and prevents any misunderstandings that may cause friction further down the line.
Training
As we discussed earlier, before merging your informational and operational technologies, your teams may not have the necessary skills and knowledge. Before ploughing ahead with the convergence, offer cross-training initiatives to nurture a mutual understanding of each department’s processes.
This will result in a more adaptable and proficient team, and learning from one another is likely to foster close working relationships.
Using the Right Tools
Everyone knows you need the right tool for the job, and IT/OT convergence is no exception. With your objectives in mind, work together with your teams to select tools that offer the right level of visibility and control. They should provide discovery, configuration, management, and security.
Phased Implementation
While it may be tempting to dive into the deep end to reach your goals sooner, you will benefit from taking a phased approach to implementation. Start with smaller projects to test integrations and security measures so you can identify and resolve any issues early.
This also gives teams time to dip their toes in and get used to new ways of working before fully wading in, helping to avoid any resistance.
Measure and Adjust
When setting your goals for IT/OT convergence, you should have included measurable metrics to assess outcomes. Once the transition is underway, it’s important to closely monitor these metrics, review them, and then make adjustments to your strategy accordingly.
This will help keep the process on track and ensure you achieve your desired objectives.
Ensure Secure IT/OT Connection With 4Secure
Without the right protections, critical infrastructure, ICS, and SCADA networks can be an open invitation to cyber threats ( not to mention compliance headaches) during IT/OT convergence.
Don’t let this happen.
4Secure offers proven, tailored solutions that allow data to flow in a controlled manner between informational and operational systems while remaining fully protected.
How do we do it? We use a unique combination of hardware-enforced security, intelligent data filtering, and deep protocol inspection to help organisations like yours achieve seamless IT and OT integration with full confidence in their security and compliance.
Since 2003, we’ve unlocked strategic and competitive advantage through innovative cybersecurity solutions.
At the heart of all 4Secure solutions is TrustedFilter®. This is our very own cybersecurity software built to deliver the data assurance that used to come only from specialist hardware.
Curious to see it in action? Let’s show you how easy secure IT/OT convergence can be.
