In today’s manufacturing environment, the gap between Information Technology (IT) and Operational Technology (OT) has become one of the most critical barriers to digital transformation. IT teams focus on data, networks, and security, while OT teams focus on production uptime, safety, and reliability. When these worlds are misaligned, the result is fragmented systems, duplicated efforts, cybersecurity risks, and stalled transformation projects.
Joltek specializes in bridging IT and OT. We design architectures and integration strategies that connect plant floor systems with enterprise technologies, ensuring data flows securely and reliably across the organization. Our goal is to provide manufacturers with a scalable foundation that not only supports today’s operations but also prepares them for advanced analytics, AI, and future digital initiatives.
We combine hands-on automation expertise with strategic IT knowledge to deliver practical integration solutions. Our approach focuses on:
1. Current State Assessment
2. Architecture Design
3. Implementation Guidance
4. Future-Proofing
A pharmaceutical manufacturer had invested heavily in SCADA and MES systems but production data was not reaching the ERP or management reporting tools. IT and OT teams operated independently with no shared data model, and integration projects had failed twice due to scope disagreements. Joltek assessed the full architecture, mapped where data was being generated and where it needed to go, and designed a Unified Namespace approach using an MQTT broker layer. The integration was deployed without production disruption and gave leadership real-time visibility into batch performance for the first time.
An industrial manufacturer with 12 PLCs and multiple SCADA stations was running a completely flat OT network with no segmentation. IT flagged the environment as a cybersecurity liability during an insurance renewal audit. Joltek designed a segmented network architecture following ISA/IEC 62443 principles, defined DMZ zones between IT and OT, and created a phased implementation plan that avoided production shutdowns. The manufacturer passed its next cybersecurity audit and reduced its cyber insurance premium significantly.
A private equity-backed manufacturer acquired two facilities with completely different SCADA platforms, separate historians, and no standardized data tags. The corporate team needed consolidated reporting but had no IT/OT integration roadmap. Joltek developed a vendor-agnostic integration architecture that normalized data from both platforms into a unified data layer. Within four months, consolidated OEE and production reporting was available to the executive team across both facilities without replacing either site's existing control systems.
IT/OT integration is the process of connecting Information Technology systems (ERP, databases, cloud platforms) with Operational Technology systems (PLCs, SCADA, MES, historians) so that data flows reliably and securely across the organization. The goal is to enable real-time visibility, better decision making, and a foundation for analytics and AI.
A Unified Namespace is a centralized data architecture where all plant and enterprise systems publish their data to a shared broker (typically MQTT-based), creating a single source of truth for the entire organization. It eliminates point-to-point integrations and makes it much easier to add new systems or analytics tools. Joltek helps organizations evaluate whether a UNS is the right approach given their existing infrastructure and maturity level.
An IT/OT architecture assessment typically takes 3–5 weeks. Implementation timelines depend heavily on the number of systems, site complexity, and whether infrastructure changes are required. Most phased integration projects run 3‒9 months. Joltek designs implementation plans to minimize disruption to live production environments.
Poorly integrated or flat IT/OT networks are among the most common sources of industrial cybersecurity risk. Unpatched PLCs connected to enterprise networks, lack of network segmentation, and missing monitoring create vulnerabilities that threat actors actively exploit. Joltek incorporates cybersecurity best practices from ISA/IEC 62443 into every architecture design to ensure integration does not increase risk exposure.
Explore these Joltek resources on IT/OT architecture and integration:
