How IT and OT convergence drives manufacturing efficiency

Manufacturers constantly seek ways to improve operational efficiency, reduce costs, and minimize downtime. But disconnected systems make these goals harder to achieve.

Operational Technology (OT) helps run a factory, and Information Technology (IT) stores, processes, and analyzes data from factory operations. Typically, these two aspects function as siloed systems. This disconnect means important machine data often doesn’t reach decision-makers. And IT or maintenance teams struggle to collaborate effectively.

As a result, inefficiencies persist, downtime increases, and response times to operational disruptions slow.

But this is changing. By connecting IT and OT systems, manufacturers create more efficient operations that reduce waste, increase uptime, and keep production running smoothly. This practical integration sets the foundation for smarter manufacturing.

In this article:

• What is IT and OT convergence?
• The cost of divided systems
• Why IT and OT convergence matters
• Case study: IT and OT convergence in action
• Common implementation barriers
• Summary

What is IT and OT convergence?

IT/OT convergence is the integration of Information Technology (IT) and Operational Technology (OT) to create a unified, data-driven manufacturing environment.

OT includes the hardware and software that control industrial processes, such as sensors, controllers, and machinery. IT encompasses the systems used for data processing, analytics, and enterprise management.

The combination of these two technology systems enables immediate data exchange and improved efficiency on the manufacturing floor.

The cost of divided systems

Most manufacturing operations rely on speed, precision, and data-driven decisions. Yet, many companies struggle with outdated, siloed systems that prevent them from operating as a connected organization.

When IT and OT remain separate, the consequences extend far beyond inefficiency—they impact every aspect of production. For example:

• Growing cybersecurity risks: Fragmented IT and OT networks create security gaps, making it easier for cyber threats to exploit vulnerabilities and compromise sensitive data and operations. With the average data breach costing $4.88 million, addressing these risks is a financial as well as operational necessity.
• Limited visibility hinders decision-making: Without real-time data from the factory floor, leadership must rely on outdated reports, making it difficult to respond quickly to production issues, supply chain disruptions, or shifting demand. And according to IDC Market Research, companies lose 20-30% of revenue every year due to inefficiencies, which involve making decisions based on incorrect or outdated data.
• Reactive maintenance drives up costs: Without predictive insights, equipment failures catch teams off guard. This leads to costly downtime, rushed repairs, and unnecessary part replacements. In fact, research shows that the average manufacturer deals with 800 hours of downtime per year—or more than 15 hours per week. And this unplanned downtime is costing industrial manufacturers an estimated $50 billion each year.
• Missed opportunities for automation: Disconnected systems limit your ability to implement analytics and automation technologies that can lead to higher efficiency and precision.

Why IT and OT convergence matters

IT and OT convergence isn’t just about connecting systems—it’s about creating smarter, more responsive operations.

With seamless data flow between machines, production lines, and business systems, manufacturers can move from reactive to predictive.

The result? Less downtime, faster decision-making, and greater efficiency at every level.

This shift is already reshaping manufacturing companies and here’s how it’s delivering results.

Predictive maintenance reduces downtime before it happens

Unplanned downtime is one of the biggest financial drains on manufacturers, costing an average of $260,000 per hour. Yet many still rely on traditional maintenance models that are either reactive or maintenance services follow rigid schedules.

Predictive maintenance can help curb this issue. By analyzing real-time sensor data with AI-driven tools, manufacturers can anticipate failures before they happen. Meaning your repairs are proactive rather than reactive.

Research from McKinsey shows this can reduce unplanned downtime by up to 50% and extend machine lifespan by 20 to 40 percent. Solutions like TeamViewer Smart Service put this into action, using remote connectivity to detect issues early, prevent breakdowns, and ensure continuous machine operation.

Real-time visibility enables smarter decisions

Disconnected systems make it harder for manufacturers to see what’s really happening on the production floor. This is because often data gets stuck in silos. This leads to delays, inefficiencies, and missed opportunities to improve operations.

When IT and OT systems converge, real-time data from machines, sensors, and business systems flows. Enabling manufacturers to monitor every aspect of the production process.

With immediate access to performance data, operators can quickly identify inefficiencies and adjust workflows before small issues escalate. This leads to smarter and faster decision-making. Armed with real-time visibility, manufacturers can adjust production schedules, reallocate resources, or fine-tune machine settings.

Remote monitoring speeds up issue resolution

Waiting for on-site technicians to diagnose and fix machinery issues is both costly and time-consuming. Every delay slows production and increases downtime.

By integrating IT and OT, manufacturers can enable remote troubleshooting, allowing technicians to identify and resolve issues without needing to be on-site. This not only speeds up repairs but also reduces travel costs and minimizes disruptions to operations.

For example, the Bühler Group, a global leader in food production systems, improved their remote support capabilities using TeamViewer Tensor. This allowed technicians to quickly diagnose and resolve issues, even in remote areas with poor internet. Thus, reducing the need for on-site visits. It also provided secure, documented support sessions, ensuring faster resolution and helping them reach ISO 27001 compliance certification.

Learn how Bühler uses TeamViewer Tensor to support its plants and customers.

Automation drives efficiency and quality

Integrating IT and OT enables manufacturers to shift from manual adjustments to fully automated systems. This change streamlines operations and reduces human error, making production more efficient.

Automating processes speeds up production cycles by removing bottlenecks and delivering consistent output. Machines reliably handle repetitive tasks, maintaining high production rates while preserving quality standards. This results in better throughput and reduced costs.

In addition, product quality improves as automated systems perform tasks with exact precision. With fewer defects and less rework needed, manufacturers get better quality and use fewer materials.

IT and OT convergence in action at the Cimbali Group

At the Cimbali Group, the world’s largest manufacturer of professional coffee machines, maintaining coffee machines and IT infrastructure were two separate operations. So, when a machine needed maintenance, the process was slow and costly. A technician had to travel on-site, diagnose the issue, and only then begin repairs. With machines installed worldwide, that often meant long delays and high service costs—frustrating both Cimbali and its customers.

To change this, Cimbali implemented TeamViewer, connecting their coffee machines to their IT network. By integrating remote connectivity into its machines, technicians could now securely access the machine's interface, diagnose problems in real time, and even adjust software settings remotely. No more waiting for a technician to arrive—issues could be resolved instantly.

The result? A 20% boost in technician efficiency, lower service costs, and machines that stayed up and running, keeping businesses—and coffee—flowing.

Discover how Cimbali Group improved its service operations.

Common implementation barriers (and how to overcome them)

Successfully combining IT and OT in manufacturing requires a clear strategy that tackles both technical and organizational challenges. While the benefits are clear, achieving smooth integration takes careful planning, the right tools, and teamwork across departments. Below, we discuss the main challenges and how manufacturers can address them.

Legacy systems create integration hurdles

Many manufacturers rely on older OT systems that weren’t designed to connect with modern IT infrastructure. These legacy systems often use proprietary protocols that don’t easily integrate.

To bridge this gap, companies can deploy industrial gateways (e.g., OPC UA, MQTT) to enable communication between disparate systems, implement edge computing for localized data processing, and leverage cloud platforms like AWS IoT and Microsoft Azure IoT for centralized analytics.

Additionally, real-time monitoring and secure remote access are critical to ensuring smooth IT/OT interaction. Remote connectivity solutions, like TeamViewer, allow IT teams to troubleshoot OT systems without disrupting production. This helps you to reduce downtime and operational costs.

IT and OT teams need to work together

Beyond technology, IT and OT convergence require collaboration. IT teams typically focus on security and data integrity, while OT teams prioritize uptime and efficiency—leading to friction.

To promote collaboration, manufacturers can implement cross-disciplinary training programs that help IT and OT teams understand each other’s priorities. Alternatively, collaborative tools, such as remote access and monitoring solutions like TeamViewer, can further boost teamwork by enabling IT teams to support OT systems without requiring on-site presence. This reduces response times and minimizes production disruptions while ensuring secure and real-time oversight.

Justifying the ROI

IT and OT integration does require an upfront investment, but the returns can also be substantial. A study by the Boston Consulting Group found that companies implementing IT and OT integration achieved an average ROI of 20 to 30% within three years. This is primarily achieved through reduced downtime, increased operational efficiency, and better resource utilization.

Summary

IT and OT convergence is changing the manufacturing industry. Offering the potential to reduce downtime, resolve issues faster, and make smarter, data-driven decisions.

While the path to integration can be challenging, the rewards outweigh the effort. Companies that successfully bridge this gap not only streamline operations but also improve their quality output and are more able to tackle production challenges head-on.

With the power of predictive maintenance, remote monitoring, and automation, your business can become more resilient and competitive.