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IT/OT Convergence Benefits: Operational Efficiency and AI Readiness

Platforms supported by security and networking help manufacturing and industrial organizations adopt a unified approach to IT and operational technology.

IN THIS ARTICLE

Agentic artificial intelligence, autonomous operations and the Internet of Things have added momentum to IT and operational technology (OT) convergence in manufacturing and industrial organizations. Organizations are increasingly looking to IoT maturity to reduce downtime, control costs and increase operational efficiency.

The challenge, however, is that fragmented systems, legacy infrastructure and security concerns continue to limit progress, with potentially serious consequences. Too often, siloed environments result in an unpleasant wake-up call when manufacturing leaders realize they lack a holistic understanding of the operations, costs and risks in their environments. Moreover, disjointed systems make it difficult or impossible to leverage AI agents and automation processes that require integrated, trusted and real-time data.

Platform modernization and data integration, supported by networking and security, help organizations create a unified plant floor approach. With the right foundations in place, organizations can converge IT and OT environments to enable scalable, intelligent and secure digital transformation.

Accelerate your IoT maturity journey with a CDW assessment or transformation workshop.

Agentic artificial intelligence, autonomous operations and the Internet of Things have added momentum to IT and operational technology (OT) convergence in manufacturing and industrial organizations. Organizations are increasingly looking to IoT maturity to reduce downtime, control costs and increase operational efficiency.

The challenge, however, is that fragmented systems, legacy infrastructure and security concerns continue to limit progress, with potentially serious consequences. Too often, siloed environments result in an unpleasant wake-up call when manufacturing leaders realize they lack a holistic understanding of the operations, costs and risks in their environments. Moreover, disjointed systems make it difficult or impossible to leverage AI agents and automation processes that require integrated, trusted and real-time data.

Platform modernization and data integration, supported by networking and security, help organizations create a unified plant floor approach. With the right foundations in place, organizations can converge IT and OT environments to enable scalable, intelligent and secure digital transformation.

Accelerate your IoT maturity journey with a CDW assessment or transformation workshop.

Satellite map

IT/OT Convergence Sets the Stage for Advanced Capabilities

Convergence between IT and OT has become a strategic priority for manufacturing and industrial organizations pursuing IoT maturity, AI and automation. However, many environments still have long-standing gaps between IT systems management and the operational technologies controlling physical operations and industrial assets. These silos impair visibility and data integration, increase inefficiency and downtime risks, and make it difficult to adopt emerging technologies at scale. One common symptom of outdated systems, for example, is an overreliance on manual rework to make data accessible and useful.

The solution is IT/OT convergence: a single, intelligent environment that aligns OT data, IT governance, security and operations. Convergence is more than a dashboard expansion or a limited connectivity play. It is an overarching strategy that CDW assesses across seven core areas: culture and synergy, strategy and governance, people and skills, process alignment, technology alignment, data management, and security and compliance. All seven are essential for true convergence. For example, connecting OT to the network without proper security increases risk by widening the attack surface without the necessary segmentation, governance and OT-specific monitoring.

In practice, physical systems and software technologies are often the easiest fix. Shifting people and processes is where many organizations struggle to achieve maturity. Others establish islands of connectivity and automation, but find it difficult to scale these advances across business units or product portfolios. As a consequence of these challenges, many organizations stay in a reactive posture, lacking unified visibility and unable to leverage capabilities such as AI-enabled predictive maintenance or agentic AI.

A holistic approach to IT/OT convergence encompasses data integration, networking, security and platform capabilities. Ultimately, IT/OT convergence helps organizations advance beyond silos by establishing one intelligent environment characterized by connectivity and integration. When organizations can transform data into actionable insights at an enterprise scale, they can improve performance, build resilience and drive innovation.

46%

The percentage of manufacturing COOs who say that data and IT/OT infrastructure are a top challenge for implementing AI in operations

Source: mckinsey.com, “From Pilots to Performance: How COOs Can Scale AI in Manufacturing,” Dec. 15, 2025

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Accelerate your IoT maturity journey with a CDW assessment or transformation workshop.

IT/OT Convergence Sets the Stage for Advanced Capabilities

Convergence between IT and OT has become a strategic priority for manufacturing and industrial organizations pursuing IoT maturity, AI and automation. However, many environments still have long-standing gaps between IT systems management and the operational technologies controlling physical operations and industrial assets. These silos impair visibility and data integration, increase inefficiency and downtime risks, and make it difficult to adopt emerging technologies at scale. One common symptom of outdated systems, for example, is an overreliance on manual rework to make data accessible and useful.

The solution is IT/OT convergence: a single, intelligent environment that aligns OT data, IT governance, security and operations. Convergence is more than a dashboard expansion or a limited connectivity play. It is an overarching strategy that CDW assesses across seven core areas: culture and synergy, strategy and governance, people and skills, process alignment, technology alignment, data management, and security and compliance. All seven are essential for true convergence. For example, connecting OT to the network without proper security increases risk by widening the attack surface without the necessary segmentation, governance and OT-specific monitoring.

In practice, physical systems and software technologies are often the easiest fix. Shifting people and processes is where many organizations struggle to achieve maturity. Others establish islands of connectivity and automation, but find it difficult to scale these advances across business units or product portfolios. As a consequence of these challenges, many organizations stay in a reactive posture, lacking unified visibility and unable to leverage capabilities such as AI-enabled predictive maintenance or agentic AI.

A holistic approach to IT/OT convergence encompasses data integration, networking, security and platform capabilities. Ultimately, IT/OT convergence helps organizations advance beyond silos by establishing one intelligent environment characterized by connectivity and integration. When organizations can transform data into actionable insights at an enterprise scale, they can improve performance, build resilience and drive innovation.

Accelerate your IoT maturity journey with a CDW assessment or transformation workshop.

Downtime, Data and Risk in Manufacturing

~$170K

The average per-hour cost of unplanned downtime in industrial organizations

44%

The percentage of organizations that do not have robust systems for moving data effectively

Source: Blue Prism, “The Global Enterprise AI Survey 2025,” March 2025

65%

The percentage of manufacturing executives who rank operational risk as their first or second concern related to smart manufacturing initiatives

Downtime, Data and Risk in Manufacturing

~$170K

The average per-hour cost of unplanned downtime in industrial organizations

44%

The percentage of organizations that do not have robust systems for moving data effectively

Source: Blue Prism, “The Global Enterprise AI Survey 2025,” March 2025

65%

The percentage of manufacturing executives who rank operational risk as their first or second concern related to smart manufacturing initiatives

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Core Capabilities for IT/OT Convergence

Connected devices, edge-to-cloud computing and platforms are the backbone of IT/OT convergence, enabling seamless data flow, real-time processing and scalable integration across environments. What matters most, however, are the operational outcomes that these capabilities deliver: increased resilience, more uptime and faster intelligence that helps organizations reduce reliance on reactive processes.

DEVICE CONNECTIVITY: From machine sensors on production lines to computer-vision cameras, devices facilitate the use of AI and automation in the physical world. Device connectivity involves the secure onboarding, monitoring and management of connected assets across distributed environments. Device deployments should be guided by strategic objectives that connect data and analytics to specific business outcomes — for instance, leveraging video intelligence insights to optimize workflows and improve operations. They enable the data collection that, at scale, drives real-time visibility into what’s happening across environments and empowers organizations through predictive insights.

EDGE-TO-CLOUD DESIGN: Hybrid infrastructures balance edge and cloud capabilities to help organizations optimize performance and increase flexibility — for example, leveraging the edge for fast decision-making near devices and the cloud for long-term storage and analytics. At the same time, plant managers often want to retain control, access and ownership of data through on-premises solutions. Rather than moving every workload to the cloud, organizations can establish a data acquisition layer close to the production environment, enabling local control over operational data while building toward broader integration over time.

DATA STREAMING: Data capture, usage and trust are essential for AI and a major roadblock for many organizations. Manufacturers effectively use only 43% of the data they collect, with the remainder being inaccessible or too untrustworthy to be actionable. Teams often spend significant time reworking spreadsheets manually to make data usable, slowing operations and maintaining reliance on historical data as opposed to forward-looking, predictive insights. Data integration platforms ease these pain points by handling high-volume telemetry with real-time ingestion and normalization, making data standardized and otherwise usable for subsequent analysis and automation. Platforms also support data streaming at scale by facilitating data collection from disparate systems and managing data flow to avoid bottlenecks.

ANALYTICS AND AI: Traditionally, data served a dashboard function, delivering insights about what already happened in an environment. By contrast, modern data is a decision driver, helping organizations look forward with a better understanding of what’s likely to happen in their environments tomorrow. Analytics and AI help organizations turn raw data into predictive insights and automation opportunities. In manufacturing, that means predictive maintenance, real-time production visibility and robotic coordination.

SECURITY AND COMPLIANCE: The connectivity that enables AI, analytics and automation can create risk if it is not managed properly. Sixty-five percent of manufacturing executives said operational risk is among their top concerns about smart manufacturing, including increased potential for unauthorized access, operational disruption and intellectual property theft. IT/OT convergence requires a rethinking of cybersecurity both holistically and through the lens of OT. For example, OT systems may have different requirements for security patching and uptime. Policies for segmentation, remote access, and identity and access management should be defined for OT environments. Regulatory requirements and other standards must be mapped against the converged environment to identify potential effects on risk and compliance.

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Scale Faster With CDW

Organizations often pursue limited digital transformation pilots without establishing a strategy for scaling across the enterprise. Projects frequently stall for the same reason: IT/OT convergence is complex, and it’s difficult to move past the pilot and into production. CDW’s services can help, from an initial transformation workshop that yields a tailored roadmap to full-scale, end-to-end execution support across people, processes and technology.

CDW’s IT/OT Convergence Maturity Assessment evaluates organizations against seven core areas: culture and synergy, strategy and governance, people and skills, process alignment, technology alignment, data management, and security and compliance.

While most vendors advise customers solely on technology, CDW believes that convergence happens in three areas: physical components, software solutions and organizational dynamics, specifically around IT/OT stakeholder alignment and culture.

CDW’s Transformation Workshop identifies business goals and OT challenges and maps them to emerging technology solutions to transform your business and enable next-generation insights.

The workshop yields insights about technology gaps and estimated ROI, a complexity index for the recommended work, an assessment of initial use cases and roadmaps for successful pilots.

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cdw

Core Capabilities for IT/OT Convergence

Connected devices, edge-to-cloud computing and platforms are the backbone of IT/OT convergence, enabling seamless data flow, real-time processing and scalable integration across environments. What matters most, however, are the operational outcomes that these capabilities deliver: increased resilience, more uptime and faster intelligence that helps organizations reduce reliance on reactive processes.

DEVICE CONNECTIVITY: From machine sensors on production lines to computer-vision cameras, devices facilitate the use of AI and automation in the physical world. Device connectivity involves the secure onboarding, monitoring and management of connected assets across distributed environments. Device deployments should be guided by strategic objectives that connect data and analytics to specific business outcomes — for instance, leveraging video intelligence insights to optimize workflows and improve operations. They enable the data collection that, at scale, drives real-time visibility into what’s happening across environments and empowers organizations through predictive insights.

EDGE-TO-CLOUD DESIGN: Hybrid infrastructures balance edge and cloud capabilities to help organizations optimize performance and increase flexibility — for example, leveraging the edge for fast decision-making near devices and the cloud for long-term storage and analytics. At the same time, plant managers often want to retain control, access and ownership of data through on-premises solutions. Rather than moving every workload to the cloud, organizations can establish a data acquisition layer close to the production environment, enabling local control over operational data while building toward broader integration over time.

DATA STREAMING: Data capture, usage and trust are essential for AI and a major roadblock for many organizations. Manufacturers effectively use only 43% of the data they collect, with the remainder being inaccessible or too untrustworthy to be actionable. Teams often spend significant time reworking spreadsheets manually to make data usable, slowing operations and maintaining reliance on historical data as opposed to forward-looking, predictive insights. Data integration platforms ease these pain points by handling high-volume telemetry with real-time ingestion and normalization, making data standardized and otherwise usable for subsequent analysis and automation. Platforms also support data streaming at scale by facilitating data collection from disparate systems and managing data flow to avoid bottlenecks.

ANALYTICS AND AI: Traditionally, data served a dashboard function, delivering insights about what already happened in an environment. By contrast, modern data is a decision driver, helping organizations look forward with a better understanding of what’s likely to happen in their environments tomorrow. Analytics and AI help organizations turn raw data into predictive insights and automation opportunities. In manufacturing, that means predictive maintenance, real-time production visibility and robotic coordination.

SECURITY AND COMPLIANCE: The connectivity that enables AI, analytics and automation can create risk if it is not managed properly. Sixty-five percent of manufacturing executives said operational risk is among their top concerns about smart manufacturing, including increased potential for unauthorized access, operational disruption and intellectual property theft. IT/OT convergence requires a rethinking of cybersecurity both holistically and through the lens of OT. For example, OT systems may have different requirements for security patching and uptime. Policies for segmentation, remote access, and identity and access management should be defined for OT environments. Regulatory requirements and other standards must be mapped against the converged environment to identify potential effects on risk and compliance.

Click Below To Continue Reading

arrow

Scale Faster With CDW

Organizations often pursue limited digital transformation pilots without establishing a strategy for scaling across the enterprise. Projects frequently stall for the same reason: IT/OT convergence is complex, and it’s difficult to move past the pilot and into production. CDW’s services can help, from an initial transformation workshop that yields a tailored roadmap to full-scale, end-to-end execution support across people, processes and technology.

CDW’s IT/OT Convergence Maturity Assessment evaluates organizations against seven core areas: culture and synergy, strategy and governance, people and skills, process alignment, technology alignment, data management, and security and compliance.

While most vendors advise customers solely on technology, CDW believes that convergence happens in three areas: physical components, software solutions and organizational dynamics, specifically around IT/OT stakeholder alignment and culture.

CDW’s Transformation Workshop identifies business goals and OT challenges and maps them to emerging technology solutions to transform your business and enable next-generation insights.

The workshop yields insights about technology gaps and estimated ROI, a complexity index for the recommended work, an assessment of initial use cases and roadmaps for successful pilots.

Accelerate your IoT maturity journey with a CDW assessment or transformation workshop.

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Microsoft Azure
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Jill Klein

Head of Emerging Technology and IoT

Jill Klein is the head of emerging technology and the Internet of Things for CDW. Jill is actively involved in the MxD Technology Advisory Committee and in industry research projects targeted at accelerating the adoption of IoT.