The world of manufacturing is constantly evolving, driven by the increasing convergence of information technology (IT) and operational technology (OT). This development is also leading to significant changes in the process industry's production environments, away from purely automated processes and towards increasingly autonomous systems.
This is the result of advanced technologies such as the Industrial Internet of Things (IIoT) and artificial intelligence, which boost efficiency and offer new possibilities for self-regulation. Learn how production in the process industry benefits from the seamless connection between IT and manufacturing levels.
The Evolution of Production Environments Through IT/OT Convergence
Traditionally, IT and OT operated as separate entities in production environments. IT systems managed data and business processes, while OT systems focused on controlling physical assets and processes. The convergence of these two areas means that data and physical processes are no longer treated in isolation. Instead, integrated systems communicate and interact, laying the foundation for advanced automation and autonomy strategies. But why is this desirable?
This convergence of IT and OT enables deeper integration of data-driven decisions into operational processes. Companies can now monitor and adjust production processes in real time based on precise data analytics and predictive models. This leads to greater efficiency and flexibility in production. In turn, this not only improves responsiveness to market changes, but also opens up new avenues for innovation in the process industry. When IT and OT function as a cohesive system, companies can respond more quickly to requirements and take proactive measures to boost productivity and quality. In short, they become faster, more flexible, and more competitive.
Why are IT and OT in Industry 4.0 becoming increasingly convergent? And what crucial role does your ERP system play in this? Explore our insights in the white paper “IT/OT Convergence in the Modern Process Industry.”
The Role of the Industrial Internet of Things (IIoT)
The Industrial Internet of Things has transformed how devices and machines communicate in a production environment. Sensors continuously collect data about the operating status of the machines and the production process, transmitting data in real time. Whether human or AI, this data can be analyzed and acted upon immediately. With no humans at the other end, constant monitoring and instant feedback allow the systems themselves to detect and correct even the slightest anomalies, often without human intervention.
Key benefits of IIoT in the process industry
- Reduced downtime: Early detection of maintenance requirements prevents production stoppages.
- Optimized operations: Automated adjustments make more efficient use of resources.
- Improved product quality: Quality is continuously monitored during production.
- Enhanced security: Security risks are automatically detected and eliminated.
- Advanced data analytics: Deeper insights into production processes enable informed decision-making.
Artificial Intelligence as a Driver of Autonomy
Artificial intelligence is increasingly being integrated into more applications, including ERP systems like SAP Business One. In the Internet of Things, it processes vast amounts of data and converts them into intelligent action points. AI algorithms can detect patterns that are invisible to human operators and make predictions that enable preventive measures before problems even arise. In autonomous production environments, AI can make dynamic adjustments to maximize efficiency, quality, and safety.
AI makes it possible:
- Automatic error correction: Identifying and correcting of errors without human intervention
- Data-driven decision making: Using extensive data to optimize strategy
- Personalized production: Customizing production processes to match individual customer requirements
- Predictive maintenance: Predicting and preventing machine failures
- Increased efficiency: Less waste thanks to precise process control
Self-Regulating Production Environments – Pipe Dream or Reality?
The ultimate stage of IT/OT convergence is the creation of self-regulating production environments. In such systems, machines can act not only reactively but also proactively. They can respond to unforeseen events and make decisions independently based on real-time data and pre-programmed objectives. These environments are characterized by their ability to self-diagnose, self-heal, and self-optimize.
The idea of fully self-regulating production environments, where machines are “in charge”, is partly a reality in advanced industrial applications. Some industry leaders are implementing aspects such as predictive maintenance, automated quality assurance, and energy-efficient operations management. However, such fully autonomous systems are not yet widespread in the process industry.
The degree of autonomy and the ability to self-regulate vary greatly depending on the size of the company, its technological maturity, and its willingness to invest. In many cases, companies are still going through periods of transition where they are gradually introducing more automation and connected technologies to get closer to the vision of fully autonomous production environments.
Read our white paper to find out why an advanced ERP system is the next logical step for your company: IT/OT Convergence in the Modern Process Industry. Read it now!
With PART into the Digital Future
The ongoing convergence of IT and OT in the process industry promises a future where production facilities manage themselves, from preventive maintenance to adjusting production in response to market changes or supply chain challenges. IT/OT convergence paves the way for a more efficient, more secure, and more productive future in manufacturing.
The evolution from automated to autonomous production environments represents a significant development in industrial manufacturing. Companies that adopt such technologies are well positioned to reap the benefits of advanced industrial automation. Now it is time to digitalize crucial processes in your business, in a way that suits you and your needs. We are here to help.
