The Power of IT-OT Convergence in Driving Manufacturing Innovation

How to achieve IT/OT convergence

Manufacturing is undergoing a critical transformation. As the boundaries between physical operations and digital technologies blur, the integration of Information Technology (IT) and Operational Technology (OT) emerges as a cornerstone of innovation and competitive edge. IT-OT convergence connects the intelligence of IT systems with the operational rigor of OT environments, unlocking new levels of efficiency, sustainability, and responsiveness. In parallel, Operations Management solutions like DELMIA Apriso sit at the intersection of IT and OT systems and help orchestrate and synchronize global manufacturing operations, bringing these domains closer together.

Gartner forecasts underscore the scale of this revolution: By 2025, 50% of large industrial organizations will use digital twins, achieving 10% operational efficiency improvements. Additionally, 75% of G2000 manufacturers will implement IT-OT integration strategies to accelerate product cycles and strengthen resilience.

What is IT/OT convergence?

At its essence, IT-OT convergence integrates two traditionally siloed domains:

• IT (Information Technology): Focused on data-driven decision-making, manufacturing enterprise resource planning (ERP) software, design systems like product lifecycle management (PLM) and analytics systems that provide strategic insights across the organization.
• OT (Operational Technology): Encompasses the hardware and software that control and monitor physical processes on the shop floor, including SCADA systems, PLCs, and IoT sensors.

The synergy of these domains results in a seamless flow of information. Real-time OT data feeds into IT systems, enhancing analytics and enabling dynamic decision-making. By incorporating solutions that support the entire lifecycle of operations—such as DELMIA Apriso—factories can bridge the gap between the virtual world of planning and the physical world of production.

Key components of IT/OT convergence include:

• Digital Twins and Virtual Twins: Virtual replicas of physical assets integrate historical performance, real-time data, and predictive models to optimize operations and reduce risks. Here, Dassault Systèmes’ concept of the Virtual Twin extends the idea of the digital twin further, providing a holistic, actionable mirror of the physical plant. This enriched virtual environment synchronizes design, engineering, and manufacturing, offering a blueprint that not only reflects what is happening but guides future improvements.
• Unified Architectures: Transitioning from outdated models like the Purdue Enterprise Reference Architecture to event-driven frameworks, such as Unified Namespace (UNS), facilitates real-time data integration across all systems.
• Edge Computing: Decentralized processing at the edge ensures that operational decisions are made closer to the source of data, reducing latency and enabling faster response times.

This convergence—supported by advanced manufacturing solutions like those found in the DELMIA portfolio—is the backbone of modern manufacturing strategies, enabling predictive analytics, autonomous operations, and real-time market responsiveness.

The Strategic benefits of IT/OT integration

As manufacturers converge their IT and OT landscapes—supported by solutions like DELMIA Apriso and guided by the holistic Virtual Twin paradigm—they unlock a powerful array of competitive advantages.

The following benefits illustrate how this integration amplifies operational efficiency, responsiveness, and sustainability, ultimately delivering a more agile, intelligent, and resilient manufacturing environment.

1. Enhanced Operational Efficiency

• Predictive maintenance powered by integrated IT-OT platforms reduces unplanned downtime by 40%.
• Automation of repetitive tasks leads to 15–20% cost savings across operations. By leveraging Virtual Twin approaches alongside digital twins, solutions like DELMIA Apriso help continuously refine production processes, improving uptime and throughput.

2.  Real-Time Operational Insights

• Unified dashboards provide actionable insights to identify and resolve bottlenecks immediately.
• Advanced monitoring systems ensure energy use aligns with production needs. When combined with DELMIA’s data integration capabilities, organizations gain richer views into performance, accelerating informed decision.

3. Agility in Decision-Making

• Integration with edge computing enables rapid adaptation to market changes.
• Machine learning models reduce supply chain inefficiencies.
• A Virtual Twin environment orchestrated by platforms like DELMIA Apriso helps respond quickly to fluctuations, optimizing everything from short-term production planning to logistics.

4. Sustainability Gains

• IT-OT collaboration supports net-zero factories through energy optimization.
• Virtual Twins—grounded in Dassault Systèmes’ definition—model energy flows, highlight inefficiencies, and inform sustainable strategies.
• By unifying these insights with digital twin infrastructures, manufacturers gain an integrated path to sustainable, profitable operations.

5. Improved Quality and Compliance

• Integrated QMS supported by real-time data catches defects early.
• IT-OT integration aligns processes with regulatory standards.
• The synergy of digital and Virtual Twin models ensures continuous improvement cycles backed by accurate, contextual insights.

6. Enhanced Workforce Productivity

• AR tools powered by IT-OT integration enable faster training and troubleshooting.
• Collaborative platforms break down silos, improving communication and knowledge sharing.
• With DELMIA’s solutions, operators can seamlessly merge virtual and physical realms. This makes it easier to understand complex workflows and helping ensure both assembly and quality tasks are performed correctly.

7. Resilience and Risk Management

• Cyber-physical systems strengthen security across IT and OT layers.
• Real-time monitoring and redundancy measures reduce risks from supply chain disruptions.
• The Virtual Twin approach reinforces this resilience by providing a trusted, accurate reference point for crisis mitigation and contingency planning.

Challenges on the road to convergence

Despite the transformative potential of IT-OT integration, many manufacturers encounter formidable hurdles. Cybersecurity threats, outdated systems, cultural divides, and skill shortages can significantly delay or derail progress.

According to recent industry analyses, nearly 60% of organizations cite cybersecurity and legacy technologies as top barriers to digital transformation, while more than half struggle with cultural misalignment and workforce readiness. Addressing these challenges is critical for unlocking the full value of integrated operations.

1. Cybersecurity Risks

• Market Insight: Over 23% of OT environments experienced cyberattacks in 2023, underscoring the urgent need for robust safeguards.
• Mitigation Strategies:
  • Adopt zero-trust architectures to control data flows tightly
  • Implement endpoint protection tailored to cyber-physical systems

2. Legacy Infrastructure

• Market Insight: Aging infrastructures are incompatible with modern IT architectures, slowing the path to real-time insights.
• Solutions: 
  • Employ event-driven architectures (e.g., MQTT, UNS) for seamless interoperability
  • Introduce modular upgrades to modernize incrementally and minimize disruptions

3. Cultural and Organizational Barriers

• Market Insight: With 55% of organizations still managing IT and OT separately, bridging the cultural gap remains a critical priority.
• Bridging the Divide:
  • Form multidisciplinary teams encompassing IT, OT, and engineering
  • Offer cross-functional training to enhance digital dexterity and collaborative mindsets

4. Skill Gaps

• Market Insight:
  • The demand for hybrid skill sets—combining domain expertise, analytics, and IoT capabilities—continues to outpace supply.
• Addressing the Gap: 
  • Partner with specialized training providers to develop AI, IIoT, and transformation competencies
    • Leverage user-friendly solutions like DELMIA to streamline complex workflows and empower a broader range of talent

Conclusion: A competitive imperative

The convergence of Information Technology and Operational Technology marks a pivotal shift in manufacturing. As Dassault Systèmes’ Virtual Twin concept demonstrates, the potential now extends beyond the traditional digital twin: it’s about transforming data into actionable intelligence that continuously guides operations. 

Combined with the capabilities of solutions like DELMIA Apriso, this holistic view of production is more than a technical improvement—it’s a strategic blueprint for long-term success. Those who embrace this integration and adopt the Virtual Twin paradigm will lead to efficiency, sustainability, and resilience. Those who do not, as Gartner warns, risk competitive irrelevance in a rapidly evolving landscape.