How to enhance your operational technology in manufacturing

In recent years, advancing technology such as digital twins, industrial internet of things (IIoT) and artificial intelligence (AI) has spurred innovation, yet physical machines are still at the heart of manufacturing. Teams that focus on operational technology in manufacturing are facing both challenges and opportunities as they integrate new technology with existing equipment. While years past saw information technology (IT) and OT in their own silos, today we're seeing a greater convergence of IT and OT.

What is operational technology in manufacturing?

The National Institute of Standards and Technology (NIST) defines operational technology as "programmable systems or devices that interact with the physical environment (or manage devices that interact with the physical environment)." Manufacturing OT includes the hardware and software that control and monitor the machines in a factory, such as the industrial control systems that support production processes.

IT focuses more on infrastructure management, cybersecurity, data management, software development and technical support for software that sales and operations teams use inside an office. Manufacturing OT is primarily concerned with the physical environment on the plant floor, with a particular focus on uptime, reliability and physical safety. However, in some organizations, IT and OT operate separately, impacting initiatives such as smart factory automation and other industry 4.0 technologies.

Smart manufacturing OT

Operational technology in manufacturing is often deployed in projects with long timelines because industrial systems and machines are expensive and expected to last many years. Safety and longevity are prioritized over user experience (UX). However, the OT decision-making process is getting more complicated with tools like cobots (collaborative robots) and automated guided vehicles and new capabilities like machine learning, digital twins and predictive maintenance. These elements of a smart factory can give manufacturers a competitive edge.

But OT implementation doesn't have to be an all-or-nothing scenario. OT teams can consider retrofitting existing tools to make them smarter. IoT capabilities can monitor equipment and systems and enable data-informed decisions about maintenance, repairs, or eventual upgrades. Such an approach to smart manufacturing empowers OT decision-makers to consider new technology investments while proactively caring for their existing assets.

Key factors for OT teams in making decisions

Operational technology teams should consider several factors when making technology decisions, especially as manufacturers continue embracing the smart factory. Industrial equipment and related control systems are on a much slower timeline than IT. Here are some key factors in OT decision-making:

• Identifying operational needs and potential productivity improvements
• Evaluating performance metrics to optimize processes and maintain legacy equipment
• Consulting with stakeholders, including management, engineers, IT staff and line workers
• Assessing physical safety concerns
• Analyzing capabilities offered by new technology
• Estimating longevity, such as the expected lifespan of new industrial control systems and the anticipated end date of the current system
• Integrating systems for streamlined workflows
• Prioritizing cybersecurity and privacy

Technologies such as the Industrial Internet of Things are critical in enabling leaders to make informed decisions. For example, IIoT data could help you adopt a predictive maintenance approach to avoid costly downtime. IIoT data can seamlessly flow through manufacturing execution systems and enterprise resource planning software. OT teams can then analyze the data from these devices, potentially with the help of AI, to identify issues and optimize the factory floor.

When rolling out new systems, OT teams should also carefully plan for any training and potential downtime that may be required.

Importance of privacy and cybersecurity

Integrating new levels of connectivity enables many benefits, but it also presents new potential vulnerabilities. The downside to embracing new operational technology in manufacturing is that advanced technology opens the factory floor to the outside world. Every connected device is a potential attack surface for bad actors. If you are expanding manufacturing OT, you must also enhance OT cybersecurity. The National Security Agency suggests:

• Hardening human-machine interfaces
• Limiting the exposure of OT systems to the internet
• Using strong and unique passwords
• Implementing multifactor authentication for all access to the OT network

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The author of this content is a paid contributor for Verizon.