The Convergence of IT & OT in Manufacturing
IT/OT convergence is the integration of data management systems (IT) with industrial operation systems (OT) and allows for real-time data exchange, enhancing the efficiency and effectiveness of both systems. Industries benefit from improved decision-making and operational processes, grounded in accurate, timely data.
What is OT?
Operational Technology (OT) refers to the combination of hardware and software designed to manage, control, and oversee physical equipment and processes in sectors like manufacturing, energy, and telecommunications.
It utilizes technologies including Industrial Control Systems (ICS) and Supervisory Control and Data Acquisition (SCADA) systems to oversee, manage, and automate industrial activities in real time. Although legacy systems are still prevalent in OT, there is a noticeable shift towards more contemporary integrations due to technological advancements.
OT plays a crucial role in amplifying the efficiency, security, and dependability of industrial processes. It achieves this by offering instantaneous feedback and control mechanisms, reducing downtime and boosting output.
Distinct from Information Technology (IT), OT is characterized by its direct engagement with industrial machinery and procedures, with a concentration on tangible environments and operational necessities.
The Difference Between IT and OT
Types of IT/OT Convergence
IT/OT convergence is not a monolithic concept, but a multifaceted initiative tailored to the specific organizational needs and goals.
Each type of convergence—physical, software, and organizational—addresses distinct aspects of the integration process. For example, this includes direct connection of devices, seamless data flow, and the harmonization of organizational workflows.
Impacts of IT/OT Convergence on ICS Security
Historically ICS sensors, instrument and devices were not accessible via an IT network and were considered safe because of the ?ir Gap" however with the integration of IT and OT systems that air gap has disappeared and previously segregated devices have become susceptible to weaponization. ICS sensors can be vulnerable to botnets used to launch targeted attacks on critical infrastructure. This includes energy grids, power plants, water and waste management systems, food processing plants, and transportation networks.
The human-machine interface (HMI) that connect operators to industrial control systems are now also typically networked to various IT infrastructures. Accessibility to HMIs from internet-facing business networks poses a risk to ICS security, making HMIs susceptible to IP-based vulnerabilities. IP-based vulnerabilities can include authentication bypass, weak session management, unsecured ICS communication protocoling and insufficient control traffic encryption.
Attackers typically infiltrate ICS systems with both generic malware and malware designed specifically to target and attack critical infrastructure. These infiltrations often result in denial-of-service, or DoS, attacks that paralyze or halt industrial operations. ICS and connected IIoT devices are also high-value targets for hackers looking to collect ransoms or sabotage rival nations by gaining access to confidential data.
The Vision for IT & OT in Manufacturing
IT/IoT and OT Components
The Role of IoT and IIoT in IT/OT Convergence
The advancement of the Internet of Things (IoT) and Industrial Internet of Things (IIoT) significantly influences IT/OT convergence.
Traditional OT devices, such as sensors, were not designed for network connectivity. This limits their function to data collection without the ability to transmit this data over a network. IoT devices are networked computing entities. They are adept at collecting, transferring, and analysing data, and play a pivotal role in facilitating IT/OT convergence.
In the industrial context, IIoT enhances the potential of IT/OT convergence by empowering OT devices with real-time data processing capabilities. This transformation is realized through the incorporation of smart sensors on industrial equipment, enabling these devices to collect and transmit data to IoT hubs or gateways. For example, on a factory floor, enhanced sensors can gather operational data and relay it over wireless networks to back-end system applications. Applications then interpret data to inform immediate actions, such as equipment maintenance, ensuring timely interventions and minimizing downtime.
The synergy of IoT and edge computing amplifies the efficacy of IT/OT convergence in industrial settings. Edge computing allows IIoT devices to process data in real time closer to the source. This reduces the need to transmit vast amounts of data over networks to centralized locations for processing. This capability is crucial in distributed network architectures common in industrial environments. In industrial environments, immediate data insights are essential for monitoring
IT/OT Convergence Challenges
IT and OT integration involves navigating through a complex terrain of technological and organizational complexities. It demands a blend of varied technologies and unification of diverse professional cultures and operational standards.
Security Concerns
OT systems vulnerability during IT integration poses a significant challenge due to increased risks of data breaches and industrial espionage. The combination of legacy OT systems with IT networks exposes larger attack surfaces.
Integration Complexity
Aligning IT and OT involves overcoming issues stemming from varied communication protocols and technology standards. Ensuring seamless data collection and connectivity from diverse OT equipment while developing APIs for cloud integration is critical.
Skill Gaps
The emergence of IT/OT convergence highlights evident skill gaps. The absence of standardized training and certifications leads to inconsistencies in managing converged systems, requiring enhanced training for IT and OT personnel.
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Organizational Barriers
Traditional silos separating IT and OT necessitate a shift in organizational culture. Enhanced collaboration and communication, along with integrated business policies and workflows, are essential to bridging this gap.
Equipment Compatibility
Balancing the modernization and replacement of legacy OT equipment with current IT technologies is crucial to optimizing cost and performance. Addressing incongruences ensures a streamlined operational environment.
Network Management
The management of connectivity and networks in a converged setting raises concerns about energy use, data transmission costs, and security. Organizations aim to achieve optimal performance while bolstering security protocols.
Supply Chain Obstacles
While IT/OT convergence offers enhanced visibility and control over the supply chain, it introduces challenges in data security, interoperability, and real-time management. The increased connectivity demands robust security protocols to protect sensitive supply chain data and ensure uninterrupted operations.
Benefits of IT and OT Convergence
Benefits of IT and OT convergence include:
Approaches to Implementing IT and OT Convergence
Improve Security by Segmenting IT and OT Traffic
Extend Identity Based Segmentation to the WAN
East-West Firewalling within Switch Fabric
Mitigate Ransomware Risk in Manufacturing
Zero Trust Network Access
Enterprise-wide Network Visibility
Network Policy Management
Network Scalability
Predictive Maintenance for Rotary Equipment
Automated Onboarding and Monitoring of Machine Vision & Video Systems
If you would like more information or would like to discuss please feel free to reach out.
Paul Harnett