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IT-OT Integration & Industry 4.0 Readiness

IT-OT Integration & Smart Factory Readiness: Preparing for Industry 4.0

Manufacturing is merging IT with operational technology. We help you plan your journey: production floor digitization, predictive maintenance, AI-driven optimization.

Manufacturing has two technology worlds:

  • IT (Information Technology): Servers, networks, ERP systems, business applications
  • OT (Operational Technology): Production equipment, sensors, PLCs, SCADA systems

Historically, these were separate. But Industry 4.0 and smart manufacturing require them to converge:

  • Sensors on equipment collect production data
  • Data flows to cloud/analytics platform
  • AI/ML identifies insights (predictive maintenance, efficiency optimization)
  • Results feed back to production floor via automated systems

This convergence is complex. Most IT leaders lack OT expertise; most OT engineers lack IT knowledge.

What We Help With:

  • Current State Assessment: Map your IT and OT environments; identify integration gaps and priorities
  • Roadmap Development: Plan your 3-5 year IT-OT integration journey
  • Technology Selection: Recommend sensors, data platforms, analytics tools suited to your operations
  • Integration Strategy: How to connect production floor to business systems; data governance
  • Pilot Projects: Start with quick wins (predictive maintenance, energy optimization) to prove ROI

Real Impact:

  • Predictive Maintenance: Shift from break/fix to predictive = 23% reduction in unplanned downtime
  • Production Scheduling Optimization: Real-time data + AI = 12-18% improvement in throughput
  • Energy Optimization: Sensor data + analytics = 8-15% reduction in energy costs
  • Quality Improvement: Real-time data analysis = 9-14% reduction in defects

Typical Engagement: £5-15k for roadmap + initial assessment; ongoing support available via retainer

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