Bridging the Connectivity Gap: Overcoming Legacy Infrastructure and Assets in Industrial Digital Transformation

Industrial manufacturing organizations often find themselves grappling with an inherent challenge: legacy devices, machines, and systems. These aging OT systems, designed for a different era of operations, typically rely on proprietary communications protocols and were never designed to share their data with other systems or make their data accessible to the organization.

While they may have been sufficient in the past, they were never intended to integrate seamlessly with modern applications or share their data across systems. This lack of integration and difficulty accessing the data creates a significant roadblock for manufacturers striving to embrace digital transformation. Without a way to connect these legacy systems to a modern infrastructure, organizations are left unable to derive the data-driven insights needed for innovation and operational efficiency.

Why Legacy Assets Need to Be Integrated

At the core of digital transformation lies the ability to collect and analyze data at scale. Manufacturers need access to real-time data to make informed decisions, optimize operations, and remain competitive in a rapidly evolving market. Yet, legacy systems often operate in silos, preventing the free flow of data across an enterprise.

Bridging these systems is essential to break down these silos. Enterprise industrial connectivity solutions are designed to address the challenges posed by disparate protocols and fragmented systems. Beyond mere connectivity, however, modern solutions must also offer to ensure that data from various sources can be contextualized and interpreted effectively.

Such capabilities are critical in transforming raw data into actionable insights and enabling seamless communication across the industrial enterprise.

See also: IT/OT Convergence Needs More Than Technology

Enterprise Industrial Connectivity Benefits

Industrial organizations face mounting pressure to modernize their operations and stay competitive in a rapidly evolving market. A critical step in this transformation is bridging the gap between legacy operational technology (OT) systems and enterprise IT systems. Enterprise industrial connectivity solutions play a pivotal role in enabling this integration, delivering numerous benefits to organizations.

Some of the key benefits that can be realized when such connectivity is available include:

Enhanced Data Accessibility and Analysis: Legacy OT systems often operate in silos, limiting data visibility and utilization. Connectivity solutions unify disparate systems, enabling seamless data flow across the enterprise. This real-time access to data empowers organizations to make data-driven decisions, improving agility and responsiveness to market demands.

Operational Efficiency: By integrating OT and IT systems, organizations can streamline processes, reduce redundancies, and automate workflows. This connectivity fosters improved asset management, better resource allocation, and enhanced production planning, leading to higher operational efficiency.

Predictive Maintenance and Reduced Downtime: Connected systems enable advanced analytics and predictive maintenance strategies. By monitoring equipment in real time, organizations can identify potential failures before they occur, reducing unplanned downtime and extending asset lifespan.

Improved Security and Compliance: Modern connectivity solutions incorporate robust security protocols, safeguarding sensitive data across OT and IT environments. They also ensure compliance with industry standards, protecting organizations from potential regulatory risks.

Scalability and Innovation: As organizations adopt new technologies, connectivity solutions provide a scalable framework to integrate emerging innovations, such as IoT devices and AI-driven tools, without disrupting existing systems.

By connecting legacy OT systems to enterprise IT, industrial organizations unlock new efficiencies, reduce risks, and position themselves for long-term growth in the Industry 4.0 era.

Teaming with a Technology Partner

Successfully bridging the connectivity gap requires more than just technology; it demands expertise and a strategic approach. This is where PTC can help. With a proven track record of helping organizations navigate the complexities of digital transformation, PTC offers the tools and best practices needed to overcome the challenges of legacy system integration.

PTC Kepware: OT-OT and OT-IT Connectivity

PTC Kepware is a leading solution for industrial connectivity, equipped to handle the diverse needs of manufacturers. Its features and capabilities include:

• Protocol Translation: Kepware simplifies communication by enabling data exchange between systems that use different protocols.
• Centralized Management: With a unified interface, Kepware makes it easier to monitor and remotely configure industrial connectivity.
• Scalability: The breadth of device connectivity and interoperability across OT and IT systems makes Kepwareto scalable across an organization; Kepware can support expanding connectivity needs as manufacturers start up, retrofit, and optimize their operations.
• Enhanced Security: Robust security measures ensure that data integrity and confidentiality are maintained throughout the connectivity process.

Why Kepware?

Kepware offers a number of benefits, including:

• The broadest, most reliable set of protocols
• 25+ years of experience across industries
• Best-in-class customer support.

A Final Word on Industrial Connectivity

Legacy systems have long been a stumbling block for industrial manufacturers aiming to modernize their operations. However, with the right tools and expertise, these challenges can be overcome. PTC Kepware is a comprehensive solution for integrating legacy infrastructure into a connected, modern industrial ecosystem.

As manufacturers plan their digital transformation strategies for the coming year, investing in robust industrial connectivity solutions like PTC Kepware will be crucial. By doing so, they can unlock the full potential of their data, streamline operations, and position themselves as leaders in the Industry 4.0 era.