OT vs IT: Understanding the Difference and Why Convergence Matters for NC Manufacturers

Operational Technology (OT) refers to the hardware and software that directly monitors and controls physical manufacturing processes, including PLCs, SCADA systems, HMIs, and DCS platforms. Information Technology (IT) manages data processing, communication, and business systems. For North Carolina manufacturers, the convergence of these traditionally separate domains creates both significant opportunities through Industry 4.0 analytics and remote monitoring, and serious cybersecurity risks that require careful management.

Key takeaway: According to Fortinet's 2025 State of OT and Cybersecurity Report, converged IT and OT systems were targeted in 75% of cyber incidents impacting manufacturing firms in 2024, while ransomware attacks in the industrial sector spiked 87% year-over-year. The Forescout 2024 report documented a 71% surge in active threat actors targeting the manufacturing sector compared to 2023.

Need OT/IT convergence expertise? Preferred Data Corporation provides integrated OT/IT management for North Carolina manufacturers. BBB A+ rated with 37+ years serving NC industry. Call (336) 886-3282 or discuss your needs.

What Is Operational Technology (OT)?

OT systems directly interact with the physical world to control manufacturing processes. For North Carolina's manufacturing base, spanning furniture, automotive parts, textiles, food processing, and aerospace components, OT is the technology that makes things move.

Key OT Components

Programmable Logic Controllers (PLCs):

• Control individual machines or production line segments
• Execute programmed logic for repetitive manufacturing tasks
• Process sensor inputs and control actuator outputs
• Examples: Allen-Bradley, Siemens S7, Mitsubishi, Omron

Supervisory Control and Data Acquisition (SCADA):

• Centralized monitoring and control of distributed equipment
• Collects data from multiple PLCs and sensors
• Provides operator visibility across the entire production facility
• Enables remote monitoring and control of processes

Human-Machine Interfaces (HMIs):

• Operator touchscreens for interacting with production equipment
• Display real-time process data, alarms, and status
• Allow operators to change setpoints and start/stop processes
• Located on the production floor at operator workstations

Distributed Control Systems (DCS):

• Control entire process plants (chemical, pharmaceutical, utilities)
• Manage continuous processes rather than discrete manufacturing
• Integrate multiple control loops into a unified system
• Provide both control and data collection capabilities

Industrial IoT Sensors:

• Temperature, pressure, vibration, flow, and humidity monitoring
• Machine health and performance data collection
• Environmental monitoring for compliance
• Energy consumption tracking

What Makes OT Different from IT

Understanding the fundamental differences between OT and IT helps North Carolina manufacturers manage convergence appropriately.

Priority Differences

Technical Differences

Protocols:

• IT uses TCP/IP, HTTP, SMTP, and standard internet protocols
• OT uses Modbus, EtherNet/IP, PROFINET, OPC UA, BACnet, and MQTT

Operating Systems:

• IT runs current Windows/Linux/macOS with regular updates
• OT often runs Windows XP, Windows 7, or proprietary RTOS that cannot be updated

Network Architecture:

• IT networks are interconnected and internet-connected
• OT networks were historically isolated (air-gapped) from IT and internet

Availability Requirements:

• IT tolerates planned maintenance windows
• OT often requires 24/7 operation with zero unplanned downtime

Why IT/OT Convergence Is Happening

Despite the differences, convergence is accelerating across North Carolina's manufacturing sector. According to Fortinet's research, 70% of OT systems are projected to connect to IT networks in the near future.

Driver 1: Industry 4.0 and Smart Manufacturing

Manufacturers in the Piedmont Triad, Charlotte, and Research Triangle are implementing Industry 4.0 initiatives that require OT data to flow to IT systems:

• Production analytics from real-time machine data
• Quality prediction using sensor measurements
• Digital twin simulations based on production parameters
• AI-driven process optimization
• Predictive maintenance from vibration and temperature data

Driver 2: Remote Monitoring and Management

The ability to monitor and manage production remotely requires IT/OT connectivity:

• Remote troubleshooting of equipment issues
• Off-site production monitoring for managers
• Vendor remote access for equipment support
• Multi-site production coordination
• After-hours alarm notification and response

Driver 3: Business System Integration

Connecting OT to IT enables automation of business processes:

• ERP production scheduling directly controls line sequencing
• Quality data automatically populates compliance records
• Energy consumption integrates with cost accounting
• Machine uptime drives maintenance scheduling
• Production counts update inventory in real time

Driver 4: Supply Chain Visibility

Connected manufacturing provides visibility that customers and partners increasingly demand:

• Real-time order status from production floor data
• Automated shipping notifications when production completes
• Quality certificates generated from inline inspection data
• Capacity planning based on actual machine utilization

The Security Risks of Convergence

Connecting OT to IT networks exposes manufacturing systems to threats they were never designed to withstand.

The Threat Landscape

According to Fortinet's 2025 report, 75% of OT attacks start as an IT breach that moves laterally into the OT environment. The Rockwell Automation 2025 cybersecurity predictions confirm that 65% of OT environments had insecure remote access conditions in 2024.

Key risk statistics:

• Manufacturing has been the top ransomware target for four consecutive years
• Over 12,000 OT cybersecurity incidents were reported globally in 2024
• 38% of legacy SCADA and PLC installations have known vulnerabilities
• One in four penetration tests finds default credentials in industrial environments
• The SANS 2024 ICS/OT Cybersecurity Report found that 64% of organizations still lack adequate OT network monitoring

Attack Scenarios for NC Manufacturers

Scenario 1: Ransomware reaches production A phishing email compromises an office workstation. The ransomware spreads across the flat network, eventually reaching the HMI computers on the production floor. All operator interfaces display ransom demands. Production stops completely.

Scenario 2: Remote access exploitation A vendor VPN connection, set up for equipment support, is compromised. Attackers gain access to the PLC programming environment and alter machine parameters, causing product defects that are not detected until customer complaints arrive.

Scenario 3: Supply chain malware A legitimate software update for your SCADA platform contains hidden malware, inserted by attackers who compromised the vendor's development environment. The malware exfiltrates production data and establishes persistent access.

Concerned about OT security risks? PDC provides OT/IT security assessments for manufacturers across High Point, Greensboro, Charlotte, Winston-Salem, and Raleigh. Call (336) 886-3282 or schedule an assessment.

Managing Convergence Safely

Convergence does not have to mean vulnerability. Properly managed, manufacturers can gain the benefits while controlling the risks.

Network Segmentation (The Purdue Model)

The Purdue Enterprise Reference Architecture provides a framework for segmenting IT and OT networks:

Level 0-1: Physical Process and Control

• Sensors, actuators, PLCs
• Completely isolated from business networks
• Access only through controlled pathways

Level 2: Area Supervisory Control

• HMIs, SCADA servers, operator workstations
• Network segmented from business systems
• Controlled data flows to higher levels

Level 3: Manufacturing Operations

• MES, production scheduling, quality systems
• DMZ between OT and IT networks
• Firewalls control all traffic between zones

Level 4-5: Business and Enterprise

• ERP, email, internet, business applications
• Standard IT security controls apply
• No direct access to lower OT levels

Data Diode and One-Way Communication

For the most sensitive environments, data diodes allow OT data to flow to IT systems for analytics without allowing any traffic to flow back into the OT network. This provides:

• Real-time production data for business intelligence
• No pathway for IT-based attacks to reach OT systems
• Compliance with the strictest security requirements
• Unidirectional data flow that is physically enforced

Secure Remote Access for OT

When remote access to OT is necessary, implement:

• Jump servers that log and monitor all sessions
• Time-limited access that expires automatically
• MFA for all remote OT access
• Session recording for audit and forensic purposes
• Vendor access only during scheduled maintenance windows
• Network access controls that limit lateral movement

OT Security Best Practices for NC Manufacturers

Immediate Actions

• [ ] Inventory all OT assets (many manufacturers do not know what is on their OT network)
• [ ] Change default credentials on all industrial devices
• [ ] Segment OT networks from IT with properly configured firewalls
• [ ] Disable unnecessary remote access to OT systems
• [ ] Implement monitoring on OT network traffic
• [ ] Back up PLC programs and configurations
• [ ] Document your OT architecture and data flows

Medium-Term Improvements

• [ ] Deploy OT-specific intrusion detection
• [ ] Implement patch management for OT systems (where possible)
• [ ] Conduct OT-specific vulnerability assessments
• [ ] Train IT staff on OT protocols and requirements
• [ ] Establish OT incident response procedures
• [ ] Implement secure remote access solutions for vendors
• [ ] Deploy endpoint protection on OT Windows systems

Long-Term Strategy

• [ ] Develop a technology roadmap for OT modernization
• [ ] Plan network architecture upgrades for proper segmentation
• [ ] Budget for replacing unsupported OT platforms
• [ ] Build OT security into capital equipment procurement
• [ ] Integrate OT security into your overall cybersecurity program
• [ ] Consider OT-specific cybersecurity insurance coverage

The Benefits of Managed Convergence

When done right, IT/OT convergence delivers substantial value to North Carolina manufacturers.

Production Optimization

• Real-time OEE (Overall Equipment Effectiveness) calculations
• Process parameter optimization through data analysis
• Automated quality detection reducing scrap and rework
• Energy optimization reducing utility costs
• Predictive maintenance preventing unplanned downtime

Business Intelligence

• Production data integrated with financial reporting
• Customer order status visible from production floor data
• Capacity planning based on actual machine utilization
• Quality trending for continuous improvement
• Compliance reporting automated from process data

Competitive Advantage

• Faster response to customer inquiries with real-time data
• Higher quality through data-driven process control
• Lower costs through energy and waste optimization
• Faster new product introduction with digital tools
• Attraction of next-generation workforce with modern technology

How PDC Manages IT/OT Convergence

Preferred Data Corporation helps North Carolina manufacturers bridge the IT/OT divide with 37+ years of manufacturing technology experience:

• Assessment: Evaluating your current OT environment and convergence readiness
• Architecture: Designing secure network segmentation between IT and OT
• Implementation: Deploying firewalls, monitoring, and secure access
• Management: Ongoing monitoring and support for converged environments
• Security: OT-specific cybersecurity services
• Integration: Connecting OT data to business systems safely

Frequently Asked Questions

Can we implement Industry 4.0 without connecting OT to our IT network?

Limited Industry 4.0 benefits are possible through one-way data collection (data diodes), but full value requires controlled bidirectional communication. The key is not avoiding connection entirely but managing it through proper segmentation, monitoring, and access controls.

How do we secure OT systems that cannot be patched?

Many legacy OT systems (Windows XP, older PLCs) cannot receive security patches. Compensating controls include network segmentation to isolate them, application whitelisting to prevent unauthorized software, network monitoring to detect anomalies, and physical access controls to limit direct interaction.

Who should be responsible for OT security in our organization?

According to Fortinet's research, 52% of organizations now place OT security under the CISO, up from 16% in 2022. For North Carolina manufacturers without a dedicated CISO, this responsibility often falls to the IT manager or is outsourced to a managed security provider with OT expertise.

What does OT/IT convergence cost for a typical NC manufacturer?

For a mid-sized manufacturer (50-200 employees) with existing OT systems, a properly segmented and secured convergence project typically costs $75,000-$250,000 for initial implementation, plus $2,000-$8,000 monthly for ongoing monitoring and management. The investment is often justified by a single prevented production disruption.

How long does it take to properly converge IT and OT networks?

A phased convergence approach for a mid-sized manufacturer typically takes 6-18 months: assessment (4-6 weeks), architecture design (4-8 weeks), segmentation implementation (8-12 weeks), monitoring deployment (4-6 weeks), and ongoing optimization. Rushing convergence without proper security creates unacceptable risk.

Related Resources

• Network Infrastructure for Manufacturing
• Industry 4.0 Implementation Guide
• Managed IT Services - Integrated OT/IT management
• Cybersecurity Services - OT security expertise
• Contact PDC - Discuss your OT/IT convergence needs

Bridge the OT/IT gap safely. Preferred Data Corporation has supported North Carolina manufacturers' technology evolution since 1987. BBB A+ rated, headquartered in High Point, serving the Piedmont Triad, Charlotte, Raleigh, and beyond. Call (336) 886-3282 or schedule your OT/IT assessment today.