Within the complexity of the integration of IT and OT, few names resonate with as much experience and expertise as David Ariens. David is the current author and co-founder of IT/OT insider, https://itotinsider.com/ . David has over 15 years of experience in the field, marked by significant contributions at industry giants BASF and AVEVA Select Benelux & Scandinavia. At BASF he was responsible for the industrial digitalisation team on the Antwerp site. 

David offers a unique perspective on the evolution of IT/OT and the importance of their convergence. David explores the direction which the industry could potentially go, and how new emerging technologies are pioneering these changes.

Dive into the interview below in what is the third episode in the series.

In recent years, the convergence of Information technology (IT) and Operational technology (OT) has transformed and rapidly evolved industrial and manufacturing sectors. A decade ago, the concept of IT/OT convergence began to take shape. The potential for accelerated business growth by combining the strengths of the two systems was monumental. However, this integration did not come without its flaws.

With the connection of the two systems, they inevitably open themselves up to potential cybersecurity attacks. As David iterates, “But in those days (2013/2014), I accessed dozens of SCADA systems all over the worlds, they were just connected to the internet, they were controlling water networks, they were controlling chemical facilities.” David illustrates the lack of knowledge in the early days of IT/OT, with many organisations failing to realise the consequences of having unprotected systems.

David emphasises further that there are new and emerging reasons for IT/OT convergence today, the main factor being data collection. David iterates, “It's the need for data that is now driving IT/OT convergence again, and I would say in a very, very rapid pace, lots of things are changing”. We see in the modern world, the necessity of data, and feedback of OT systems, provided by IT, is a necessity.

In today’s world, whether it be technological or business based, the buzz around AI is enormous. However, there are significant gaps between the strategic visions and ideas constructed at an executive level, and the capabilities from a shop-floor perspective. Many business leaders are pushing for vastly complicated AI endeavours when in reality, AI has not reached those capabilities yet.

David emphasises this saying, “There is this gigantic, I would say distance between what is currently possible, or I would say what people need on the shop floor, versus what the market is offering.” David highlights the importance of recognising the limitations in capabilities of AI and the importance of recognising this in relation to growth.

In addition to this, David encourages the promising ability of AI to understand data through mathematical equations. He states, “Obviously Gen AI is not able to understand data. But what you could do is use Gen AI to translate a business problem into a mathematical problem and then apply the mathematical results to the underlying data.”

The intricacies of data integration in manufacturing are immense, containing important issues such as security, privacy, and data ownership. These issues must be carefully managed to ensure smooth and secure data flow from systems to end-user applications.

Traditionally, the Purdue model was used to manage data flow in manufacturing, but the rise of IoT has introduced new complexities. Modern digital sensors now possess multiple data points, including maintenance needs and operating conditions. David emphasises, "Integrating this wealth of information into existing systems securely and efficiently is a major challenge," David provides a personal example in the water and wastewater industry, IoT sensors are embedded both in network infrastructure and customer homes, raising significant questions about data security and integration.

Data exchange has evolved to include both local systems and cloud-based solutions. However, security is often an afterthought. "Ensuring data is secured at every stage to prevent unauthorised access and manipulation is crucial," David explains. Advanced AI algorithms, for instance, might optimise operations, but ensuring the accuracy and security of the data driving these decisions is crucial to prevent catastrophic outcomes.

It is no secret that a variety of digital transformation and integration projects fail. David alludes to the fact, “around 70 % of digital transformation projects fail”. This is for a variety of reasons, but primarily due to lack of understanding of the actual business case or due to an endeavour in overly complex technologies.

A key reason for failure is the lack of a clear business case. "You need to understand the 'why' behind the project and link it to someone's job," emphasises David. The case needs to be understood from management, down to the technological experts implementing it. It must be clear and concise and the return, whether that be through profits or efficiency, must be carefully analysed.

In addition to this, David alludes to two very important points in relation to data collection. Firstly, he states “data which lives on paper, it's not information, it's just a number. And it's pointless.” If the data collected is not streamlined in the correct directions, then there is ultimately no significance of having it. In addition, the validity of the data must be checked. Data which is not secure and honest, can be time-wasting and cause decisions to be made which go against the reality of the situation.

 “If I had a crystal ball, I’d probably be lounging on my yacht.”, quips David. The complexity and lack of visibility in relation to the direction which IT/OT convergence could follow is endless. It can often be difficult to predict quarterly how digitisations will change industrial environments let alone years in advance. However, educated guesses and analysis of upcoming innovations can provide visibility into this unknown.

The shift from local-based systems to cloud environments is becoming increasingly significant, however there are still numerous steps needed before this is a complete reality. The journey to seamlessly integrate sensor data into these environments involves considerable manual effort and programming. However, advancements are on the horizon. Data science tools are becoming more accessible, reducing complexity and enabling process engineers to leverage data more effectively.

Despite these advancements, manufacturing and infrastructure industries remain cautious. They lag behind consumer-facing sectors, prioritizing the safe and reliable operation of existing assets over adopting new technologies. This hesitant approach leaves room for innovators to accelerate their technological advancements, before their competitors.,the key being to do so safely.

As David concludes, "We add new technologies only when they actually make sense." This measured strategy balances innovation with the cautious approach which business leaders should take. Innovate in areas which are needed, this way the outcomes can be clearly felt, and the business case is clear for all parties involved. 

David emphasises the necessity of integrating IT and OT for business growth, despite the possible fears that industry leaders may have. He discusses the limitations and potential of AI in manufacturing, discussing its capability of translating business problems into mathematical solutions. David also addresses the complexities of data integration, stressing the need for clear business cases and secure, valid data in digital transformation projects. Looking ahead, he advocates for a cautious yet innovative approach to adopting new technologies, balancing safety and reliability with technological advancements. His insights offer a unique and interesting view of the future direction of IT/OT convergence in the manufacturing industry.

We would encourage everyone to head over to the IT/OT insider https://itotinsider.com/ . David has authored some fantastic articles and conducted some very interesting interviews. 

Watch the Interview in Full Below 👇