Delivery Governance
IT/OT Architecture and Integration
Building the digital backbone for modern manufacturing
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.
Why it matters
What this costs when it is left alone
The reasons this work gets deferred are usually the reasons it gets expensive.
Disconnected systems lead to inefficiency
SCADA, MES, ERP, and historian platforms often operate in silos, making it difficult to access actionable insights.
Security risks increase without alignment
Unpatched controllers or poorly segmented networks create vulnerabilities that IT teams cannot see.
Data is collected but not usable
Without standardized integration, valuable plant floor data never reaches decision makers in a meaningful way.
Transformation efforts stall
Without a robust IT/OT foundation, digital transformation projects fail to scale beyond pilots.
Our approach
How the work runs
We combine hands-on automation expertise with strategic IT knowledge to deliver practical integration solutions. Our approach focuses on:
Current State Assessment
- Reviewing SCADA, MES, ERP, and historian systems
- Mapping data flows between plant floor and enterprise systems
- Identifying gaps, risks, and redundancies
Architecture Design
- Developing vendor-agnostic integration roadmaps
- Establishing a Unified Namespace (UNS) or other standardized data layer
- Designing secure, scalable IT/OT networks and data pipelines
Implementation Guidance
- Supporting vendor selection and solution deployment
- Aligning IT and OT teams on roles, responsibilities, and governance
- Defining KPIs for data availability, latency, and reliability
Future-Proofing
- Ensuring architectures can support advanced analytics, machine learning, and AI initiatives
- Building cybersecurity resilience through segmentation and monitoring
- Planning for obsolescence and long-term maintainability
What we deliver
What you end up holding
- A clear, independent assessment of your IT/OT environment
- A practical integration roadmap aligned with business goals
- Risk identification and mitigation strategies
- Guidance and training to ensure cross-team alignment
- A scalable architecture that unlocks data and supports future digital growth
Who we support
Who this is for
- IT Leaders
- responsible for network, security and enterprise integration.
- OT Leaders
- managing SCADA, PLC, MES and plant-floor reliability.
- Executives and Investors
- who need assurance that the architecture supports long-term strategy.
Why Joltek
What you are actually buying
Deep Technical Knowledge
We have hands-on experience with PLCs, HMIs, SCADA, MES, and ERP systems across multiple industries.
Strategic Alignment
We ensure technology architectures align with business outcomes, not just technical requirements.
Independent Perspective
As a vendor-agnostic consulting firm, we recommend solutions based solely on what works for your business.
Client scenarios
What this looks like in practice
Anonymised engagements. Client names are withheld; the situations are not.
Pharma Manufacturer — SCADA Data Locked in Silos
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.
Industrial Manufacturer — Cybersecurity Exposure from Flat OT Network
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.
Multi-Plant Acquisition — Incompatible Systems Post-Merger
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.
Questions
Answered before you ask
What is IT/OT integration in manufacturing?
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.
What is a Unified Namespace (UNS) and should we use one?
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.
How long does an IT/OT integration project take?
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.
What cybersecurity risks does poor IT/OT integration create?
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.
Have a project that needs technical ownership?
Send us the situation. If it is not something we should take on, we will say so.