IT-OT integration is the convergence of a manufacturer’s information technology (IT) systems — such as ERP, finance, and business intelligence — with its operational technology (OT) systems, which include the machinery, SCADA systems, PLCs, sensors, and control networks that run the production floor. Industry 4.0 requires manufacturers to connect these environments in order to achieve real-time production visibility, predictive maintenance, and data-driven decision making. Achieving this convergence safely is one of the most technically complex challenges in modern UK manufacturing.
UK manufacturers investing in new machinery or production lines and wanting connected, data-generating assets from day one — as well as those with significant installed OT equipment currently isolated from business systems. Particularly relevant to companies facing pressure to demonstrate smart manufacturing capability, traceability, or real-time production reporting.
Manufacturing is merging IT with operational technology. We help you plan your journey: production floor digitization, predictive maintenance, AI-driven optimization.
Typical Engagement: £5-15k for roadmap + initial assessment; ongoing support available via retainer
Your production equipment (machines, sensors, PLCs, SCADA systems) needs to talk to your business systems (ERP, planning tools, analytics). When they do, you get real-time visibility into your shop floor and the ability to make better decisions, faster.
Today, most manufacturers operate these as separate worlds. Industry 4.0 is about closing that gap — not with a massive transformation programme, but through practical, incremental steps that prove ROI at each stage.
Buying sensors before defining the business problem
OT security is fundamentally different from IT security
Committing to full rollout before proving concept on a single line
IT-OT integration requires IT, operations, and engineering collaboration
OT systems run legacy software that can’t be patched, operate on protocols IT teams don’t understand (Modbus, OPC UA, MQTT), and cannot tolerate downtime. We design integration strategies with proper network segmentation and OT-specific access controls.
We’ll help you select, negotiate, and govern your ERP investment.
You don’t need to build a smart factory overnight. We recommend starting with focused pilot projects that deliver measurable results within 3–6 months:
Each pilot proves the value of IT-OT integration with minimal risk. Success builds the business case for broader rollout.
It’s connecting your production equipment (machines, sensors, control systems) to your business systems (ERP, analytics, planning tools) so you can see what’s happening on the shop floor in real time and make better decisions.
Our initial assessment and roadmap engagement costs £5–15k. Pilot projects typically run £15–30k. Full factory integration varies widely depending on scale. We design phased approaches so you invest incrementally based on proven ROI.
Almost certainly not. Most manufacturers have a mix of old and new equipment. Retrofit sensors and edge computing devices can bring legacy machines into a connected environment without replacing them. We assess your specific equipment and recommend practical solutions.
Pilot projects typically deliver measurable ROI within 3–6 months. Predictive maintenance and energy monitoring are the fastest wins. Broader integration programmes show compounding returns over 12–24 months.
No. IT-OT integration is about connecting what you already have, not replacing it. We work with your existing ERP, MES, and production equipment. See our ERP & Digital Transformation service if you’re also considering an ERP upgrade.
This is critical. Connecting production equipment to your network creates risks that standard IT security doesn’t address. We include OT security assessment and network segmentation in every integration plan. Your production systems stay protected.
A practical, no-nonsense security checklist built specifically for UK manufacturers. Covers network segmentation, access controls, OT security, incident response, and compliance — everything you need to assess and strengthen your manufacturing IT security posture.
PDF Guide
