Operational Technology, better known as OT, refers to the technologies – both hardware and software – that control and monitor physical processes in industry.
This applies, for example:
- PLCs (Programmable Logic Controllers)
- SCADA systems (Supervisory Control And Data Acquisition)
- HMIs (Human Machine Interfaces)
- OT devices (robots, production cells, etc.)
- Sensors, actuators and motor controllers
In a nutshell: OT is the technical system that ensures that all production equipment works efficiently and safely.
In many companies, OT is no longer a closed automation area. Instead, it has merged with IT.
This opens up a wide range of digitalization and efficiency opportunities, but also an increased security risk with potential hacker attacks and increased focus on cybersecurity. We look at both in this article.
OT and IT – two worlds merging
Historically, OT and IT have been separate worlds. IT has handled office networks, users, databases and business applications, while OT has typically operated in isolated, proprietary networks with little or no external access with a focus on control and physical security.
| Feature | OT | IT |
| Primary focus | Machine control and production | Information, networking and business |
| Requirements | Stability, real-time, uptime | Scalability, security, compliance |
| Update frequency | Rare, due to testing and operational requirements | Often, with patches and hotfixes |
| Priority | Safe operation and uptime | Data integrity and network security |
Today, the boundaries are more blurred. For effective production management, production data must flow seamlessly and in real-time between OT and IT systems to connect and utilize data from e.g. sensors, ERP and MES.
This integration – often referred to as IT/OT convergence – is an important part of Industry 4.0.
The role of MES in OT
MES acts as the layer – or bridge – between OT and the business systems (IT). Where OT records and controls production in real time, MES collects this data and translates it into overview, decision-making and process optimization. MES also retrieves data from the ERP system to supplement data that is missing for full automation in the OT layer.
The MES system uses data from PLCs, SCADA and sensors, for example, to:
- Calculate KPIs like OEE and downtime
- Activate workflows or alerts for deviations
- Ensure traceability at batch level
- Coordinate production with ERP and planning systems
Without MES, OT data often remains local and isolated. With MES, the OT data network becomes more operational and can be better utilized across the organization.
OT security in an IT/OT integrated production environment
IT security has been on the agenda for many years, but OT security has only recently come to the fore in industry. This is largely due to the increased network integration between OT and IT, which has led to an increasing number of cyberattacks on industrial systems with potentially huge economic and societal consequences. But compliance requirements and the NIS2 directive also play a significant role.
As OT and IT merge, new attack surfaces emerge. OT environments therefore require a customized security strategy that could include the following:
- Network segmentation
- Separate zones and firewalls between OT and IT
- Monitoring and logging irregular behavior
- Long-term patch management and physical access control
OT safety in a manufacturing company
OT security in manufacturing companies is about protecting the systems that control and monitor physical processes. This includes everything from PLCs and SCADA to sensors and production equipment. In a modern factory, OT security includes both technical and organizational measures:
Network security
Segmentation, firewalls and monitoring of communication between systems.
Physical security
Protecting access to e.g. control rooms.
System hygiene
Updating firmware, removing default users and secure configurations.
Access management
Roles and rights – who can do what, when and from where?
The goal is to reduce the risk of unauthorized access, corrupted data and downtime, while maintaining high production uptime and efficiency.
MES in support of OT safety
A modern MES system not only plays a role in production planning and performance, it can also be an important part of your OT safety. MES helps to manage and understand production and can support safety, but are not safety systems in themselves. This is because the primary purpose of security systems is to protect and prevent attacks, leaks and operational losses.
Here are some of the areas where MES can help strengthen your manufacturing company’s OT safety:
Real-time monitoring and alerting
MES can detect anomalous behavior in process data and give operators and system managers early warnings, such as unexpected downtime, changes in machine parameters or deviations in consumption patterns.
Audit trail and traceability
MES logs incidents and changes. It supports compliance and provides documentation in case of a security breach.
User access and roles
Through MES, you can control access to machines and production systems based on user roles. This reduces the risk of accidental or unauthorized actions.
Centralized data insights
By gathering OT data in one platform, companies gain visibility and the ability to analyze vulnerabilities across equipment and production lines.
When MES and OT security are combined, it creates not only better operations, but also a more robust and controlled digital infrastructure.
Questions?
Do you have questions about how you can merge your production IT even better with your operational equipment? Or how MES can strengthen your OT safety? Contact us for a conversation about your situation.