IT/OT integration
What Does IT/OT Integration Mean?
IT/OT integration refers to connecting Information Technology (IT) systems and Operational Technology (OT) systems into a unified whole. IT includes enterprise systems such as databases, networks, and ERP solutions, while OT manages physical processes and equipment such as industrial automation, sensors, and control systems.
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Principal Technology Consultant
Mikko Viskari
050 465 1322
mikko.viskari@forgedigital.fi
IT/OT INTEGRATION
Typical Problems Addressed by IT/OT Integration
Limited visibility into operations
Operational data is fragmented, and there is no real-time overview of production or process performance.
Cybersecurity and network challenges
OT systems are not always sufficiently protected or they are connected to IT networks without proper security controls.
Manual and error-prone processes
Data transfer between IT and OT systems is often slow, manual, and prone to human error.
Production inefficiency and downtime
Machine data is not used proactively; issues are only addressed after they occur.
Excessive data volume overwhelming IT systems
Operational technology generates high-frequency, high-volume data streams that can overwhelm traditional IT infrastructure. Without proper data management, raw operational telemetry saturates processing and storage systems, causing performance degradation, cost escalation, and delayed analytics.
Slow response to change
IT and OT silos slow down decision-making and hinder operational agility.
Lack of interoperability and standards
Systems from different vendors are not standardized and cannot communicate effectively, limiting the use of data.
What a Well-Executed IT/OT Integration Enables
It provides real-time visibility across the entire organization – from production to business management. When operational data is integrated with IT systems, it becomes possible to monitor production efficiency, energy consumption, and equipment condition in a single view, improving the quality and speed of decision-making.
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Integration enables predictive maintenance and resource optimization. Sensor data and analytics help detect anomalies before failures occur, reducing downtime and extending equipment life. At the same time, it allows for optimization of material flows and energy use.
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IT/OT integration supports digital transformation and new business models, such as remote monitoring, flexible production control, and data-driven services. When data exchange is secure and standardized, the organization can continuously improve operations and maintain competitiveness.
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Key Success Factors for a
Successful IT/OT Integration Project
Success requires IT and OT teams to work toward a shared vision and goals. Executive support, clear responsibilities, and a common language (terminology, processes, objectives) are critical.
Shared strategy and collaboration
Cybersecurity and risk management
Integrating previously separate networks brings new risks. A layered defense model (defense in depth), access control, and strict network segmentation are essential to prevent IT-side vulnerabilities from reaching OT environments.
Standardized interfaces and interoperability
Integration only succeeds if systems can communicate reliably. This requires open interfaces, standardized data models (e.g., OPC UA), and a scalable architecture that supports future expansion.
Useful data must be accurate, up-to-date, and contextualized. Integration must ensure that operational data is easily accessible to IT systems without delays or inconsistencies.
Data quality and real-time availability
Change management
and competence development
Technology alone is not enough – success depends on people. Staff must be trained to understand both IT and OT perspectives, and the organization must be guided toward a data-driven culture.
Separate lifecycles and maintenance windows
IT systems require regular updates and patches to maintain security, while OT systems prioritize continuous uptime and stability. IT/OT integration architecture must allow IT maintenance, security updates, and changes without impacting operational availability or requiring production downtime.
Our Core Capabilities in IT/OT Integration Projects
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We master key industrial communication protocols and integration technologies. We understand how to connect different device and system layers securely and efficiently.
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We know what data can be collected from various production devices – both technically and practically – and how to transform it into usable information. This enables realistic and cost-efficient implementations.
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We understand the safety and reliability requirements of OT environments. Our solutions balance availability, security, and data protection.
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Our team combines strong backgrounds in industrial automation, information systems, and software engineering. Experience from cross-domain projects helps us apply best practices and avoid common pitfalls.
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We don’t view integration as a purely technical exercise. We understand what truly matters to industrial businesses and deliver solutions that support both operational and strategic goals.
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We go beyond reading and analyzing data — we also enable control and optimization of equipment and processes, creating a genuinely bidirectional IT/OT connection.
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We leverage artificial intelligence at the device and field level. Edge AI solutions enable real-time analysis and prediction directly on-site, without dependency on cloud connectivity. Edge computing filters, aggregates, and processes operational data locally, ensuring only relevant information reaches enterprise systems. This drastically reduces data volume while preserving critical insights.
FIDI - Forge Industrial Data Integrator
Forge Industrial Data Integrator "FIDI" is an industrial data integration accelerator that enables rapid development of IIoT (Industrial IoT) solutions through standardized, modular components.
FIDI addresses critical integration challenges including cloud connectivity, data source compatibility, system configurability, operational resiliency, and security.
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