IT/OT integration
Powered by Digital Twin - IndustryOS™
Integrating IT (Information Technology) and OT (Operational Technology) systems is transforming industries by enhancing efficiency, data-driven decision-making, and operational agility. In today’s digital age, IT/OT convergence is crucial for seamless communication between enterprise-level systems and industrial processes. By uniting these traditionally separate realms, organizations can unlock real-time insights, predictive maintenance, and optimized performance. Whether it’s in manufacturing, energy, or transportation, IT/OT integration drives innovation, reduces downtime, and increases productivity. This holistic approach ensures that technology is not only supporting but also advancing critical operations, paving the way for smarter, more connected industrial ecosystems.
First Step to Bring all Your Real-Time Data Together For Consumption.
In the fast-paced realm of process industries, where efficiency and agility are paramount, IT/OT integration emerges as the catalyst for data-driven transformation. By uniting the realms of information technology and operational technology, organizations break down data silos, enabling the seamless collection and analysis of real-time data from across the plant floor. This integration empowers process industries to gain a holistic view of their operations, enabling proactive monitoring, predictive maintenance, and optimized production processes. Furthermore, IT/OT convergence facilitates advanced analytics, enabling data-driven insights that drive innovation, reduce downtime, and enhance overall operational efficiency.
Navigating the Challenges of Integrating
Process / Shop Floor Data
Data Transparency & One version
PLC, DCS, OPC & Stand-alone Sensors
Security Risks, Making it Compliant
Optimizing Factories / Plants
-
Shop Floor Data Transparency Digital success relies on complete visibility of data across all levels. Without uninterrupted data flow, systems like MES, PLC, DCS, OPC or ERP become inefficient, limiting the ability to make data-informed decisions.
-
Overcoming Integration Challenges Sparrow tackles integration hurdles like security risks and outdated technology to connect OT and IT systems efficiently and securely, including OPC UA / DA.
-
Steps to Achieving IT/OT Integration IT/OT integration at Sparrow involves connecting production, utility, and other equipment, standardizing interfaces, and implementing advanced tools for data analysis and management.
-
Optimizing Plant Elements Sparrow boosts productivity with Totally Integrated Automation (TIA), streamlining data flow, minimizing engineering time, and enhancing overall operational efficiency. Including predictive & prescriptive analytics for yield, OEE, Maintenance, EHS, Process Risk, & Sustainability.
Explore Real-World Industrial Applications
Integrating IT and OT with IndustryOS™, enhanced by AI capabilities, offers a world-class solution for optimizing Overall Equipment Effectiveness (OEE). This integration bridges the gap between information technology and operational technology, enabling seamless data flow and real-time analytics. By leveraging IndustryOS™ and AI, businesses can monitor and improve production processes, reduce downtime, and enhance efficiency. AI-driven insights provide predictive maintenance and intelligent decision-making, resulting in a significant boost in productivity and operational performance. This makes it an essential tool for modern industries aiming to stay competitive and achieve excellence in their operation
In multiple sectors, IndustryOS™ connects real-time sensor data from manufacturing equipment with quality control systems. AI algorithms instantly analyze this data, flagging deviations from quality parameters. If a tablet press produces tablets outside weight specifications, the system alerts operators, allowing immediate adjustments. This prevents batches of substandard products, saving time, resources, and safeguarding patient safety. IndustryOS™ with AI transforms quality control from reactive to proactive, ensuring excellence in every product. This real-time approach minimizes waste, reduces production costs, and upholds the highest standards of manufacturing.
AI predicts future GHG data by leveraging advanced algorithms and data analytics. It uses historical data, real-time information, and various external factors such as weather patterns and production schedules to create predictive models. This data is processed through AI algorithms that mimic human brain functions to predict real-time and future GHG emissions linked to OEE, quality, and balance of process (BOP). Using IT/OT integration alongside IndustryOS™ and its AI capabilities, we can optimize GHG emissions as they are directly linked to planned production and plant OEE in real-time. This integration enables seamless data flow and real-time analytics, allowing businesses to monitor and adjust production processes to minimize emissions.
This integration bridges the gap between information technology and operational technology, enabling seamless data flow and real-time analytics. By leveraging IndustryOS™ and AI, businesses can monitor and improve maintenance processes, predict potential issues, and prescribe solutions before problems arise. Industries such as manufacturing, chemicals, and FMCG benefit significantly from this, resulting in reduced downtime, enhanced efficiency, and a boost in productivity. This makes it an essential tool for modern industries aiming to stay competitive and achieve operational excellence. Multiple sectors are also seeing improvements in operational performance and cost savings.
Leveraging the power of IndustryOS™ and AI to unify IT and OT presents a cutting-edge approach to yield optimization. This convergence breaks down barriers between information and operational technologies, paving the way for unhindered data exchange and instantaneous analysis. With the combined capabilities of IndustryOS™ and AI, enterprises can actively supervise and refine production workflows, anticipate potential complications, and proactively implement solutions. This translates to heightened efficiency, minimized waste, and a substantial upswing in yield. Sectors like manufacturing, agriculture, and pharmaceuticals stand to gain immensely, realizing heightened productivity and operational prowess.
Navigating Data Collection to Full Integration: A Comprehensive Guide
Achieving digital transformation requires ensuring complete data visibility from the production floor to the IT infrastructure. Without this transparency, any orchestration system—be it a traditional MES, ERP, or cutting-edge AI—will lack direction and efficacy. Effective decision-making depends on reliable data, and this necessity extends to any system that aids in human decision-making through data.
Foundation
Building a Foundation for Seamless Data Integration
To start, ensure you have access to all critical sensors, automation systems, machinery, and processes required to gather and provide essential measurements and data. This setup can be achieved for both new and existing facilities. Following this, standardize the interfaces between OT and IT, ideally using industry standards such as OPC UA. These standardized data models will enhance visibility across the plant. Additionally, implementing industrial security measures will safeguard your data and infrastructure from cyber threats. Our team of service experts is here to assist with guidance and support in these areas.
Harmonizing
Harmonizing and Contextualizing Data for Optimal Use
To fully utilize acquired data, it must be harmonized and contextualized, which requires early collaboration between OT and IT departments. Industrial Edge facilitates the use of IT solutions for managing data on the shop floor. Additionally, HMI and SCADA systems enable the integration of production with IT systems. If needed, a cloud connection can be established to further process the data.
Analysis
Leveraging IT Integration for Enhanced Analysis and Management
Connecting the shop floor to IT enables the use of analytical tools to enhance various aspects such as ecological footprint management through power monitoring or improving planning, production execution, quality management, and inventory control with an MES system. Analysis software—whether local or cloud-based—extracts data and provides valuable insights for end-to-end solutions, including visualization of complex information as defined by KPIs.
Digital twin
Digital twin
Integration
Seamless Machine Integration and Cybersecurity with OPC UA
Using the OPC UA standard, both existing and new machines can be integrated on-site without disrupting production. This standard allows for direct connections to MES or IT systems, or via line controllers. The Defense-in-Depth approach based on IEC 62443 ensures robust protection against increasingly sophisticated cyber threats. This setup provides companies with secure, transparent production processes and valuable insights, leading to optimized productivity, quality, efficiency, and flexibility.
Gain from IT/OT Integration in Automation
Discover how integrating IT and OT can transform your automation processes, providing greater efficiency, scalability, and real-time insights
Scalable IT/OT Integration
Harmonized IT/OT data exchange and systems facilitate scalability in your digital transformation journey, promoting effective collaboration among system stakeholders. As demand grows, your systems can expand accordingly.
Optimized Environmental Impact
Increased transparency offers a comprehensive view of all critical data, enabling you to optimize environmental impacts, reduce CO₂ emissions, and cut costs across various locations.
Flexible Data Response
Integrating all relevant data allows you to quickly adjust schedules and adapt flexibly to changes in customer demands, market conditions, and unexpected breakdowns.
Optimized platforms
Maecenas accumsan, elit id hendrerit convallis, lectus lacus fermentum nisi.
Faster transaction approval
Maecenas accumsan, elit id hendrerit convallis, lectus lacus fermentum nisi.
Support available 24/7
Maecenas accumsan, elit id hendrerit convallis, lectus lacus fermentum nisi.