The Hidden Risks of IT/OT Misalignment

Unclear network ownership, inconsistent patching and aging systems are costing manufacturers. Here's how a strategic integration of IT and OT changes that.

Eric Medecke

Feb. 23, 2026

3 min read

Key Highlights

Assessments are the critical first step, revealing vulnerabilities, infrastructure gaps and a prioritized remediation path.
Multi-site manufacturers gain consistency and scalability when standardized approaches replace fragmented networks.
A unified IT/OT approach lays the groundwork for predictive analytics, digital twins, and AI-driven optimization.

As manufacturers navigate the complexities of modern production, one challenge consistently rises to the top: the convergence of information technology (IT) and operational technology (OT).

Historically, these two domains operated in silos, IT focused on enterprise systems and cybersecurity, while OT managed plant-floor equipment and uptime. Today, the merging of these worlds is essential to the efficiency, security and scalability of any manufacturer’s operation.

The push toward digital transformation, coupled with increasing cybersecurity threats, has made IT/OT integration a strategic priority. Manufacturers face mounting pressure from insurance companies and regulatory bodies to meet cybersecurity compliance standards. At the same time, aging infrastructure and fragmented networks create vulnerabilities that can lead to costly downtime and production delays.

When IT and OT teams fail to collaborate, the result is often unclear ownership of network security, inconsistent patching practices, and limited visibility into connected assets. These gaps not only increase risk but also hinder modernization efforts.

Common pain points driving change

Manufacturers typically begin exploring IT/OT integration when they encounter one or more of these challenges:

Cybersecurity compliance: Insurance requirements and industry regulations demand stronger security postures.
Aging infrastructure: Legacy systems and obsolete hardware create operational inefficiencies and security risks.
Network anomalies and downtime: Poorly segmented networks and unclear responsibilities lead to unexpected outages.
IT/OT misalignment: Lack of collaboration between teams slows decision-making and complicates modernization projects.

Use assessments to uncover gaps, inform budgeting and guide modernization efforts. For multi-site operations, assessments help prioritize investments and create a roadmap for consistency.

These issues often surface during audits, after a security incident or when planning for expansion. Addressing them proactively can prevent disruptions and position manufacturers for long-term success.

The role of assessments

While manufacturers rarely start by requesting an IT/OT assessment, this step is critical for building a modernization roadmap. An assessment provides:

Visibility: A comprehensive inventory of assets and identification of vulnerabilities.
Gap analysis: Understanding where each facility stands in terms of security and infrastructure readiness.
Actionable insights: Prioritized recommendations for remediation and future improvements.

For multi-site organizations, assessments offer additional value by enabling standardized approaches across facilities. This consistency simplifies compliance, reduces complexity, and supports scalability.

Building a foundation for smart manufacturing

IT/OT integration is more than a technical exercise; it’s a strategic enabler. A unified approach allows manufacturers to:

Implement secure, routable networks with remote access capabilities.
Reduce risk during migrations from legacy systems.
Prepare for advanced initiatives such as predictive analytics, digital twins and AI-driven optimization.

Ultimately, bridging the IT/OT gap creates a foundation for smart manufacturing, where data flows seamlessly from the plant floor to enterprise systems, enabling real-time decision-making and continuous improvement.

Practical steps manufacturers should take to build this foundation include:

Start with collaboration. Bring IT and OT teams together early to define roles, responsibilities, and shared goals. This alignment is critical for avoiding conflicts and ensuring smooth implementation.
Prioritize cybersecurity. Compliance is no longer optional, insurance and regulatory requirements make it a business imperative. Begin with network segmentation, patch management and secure remote access.
Leverage assessments strategically. Use assessments to uncover gaps, inform budgeting and guide modernization efforts. For multi-site operations, assessments help prioritize investments and create a roadmap for consistency.
Think long-term. IT/OT integration is not a one-time project but an ongoing journey toward resilience and innovation. Plan for scalability and future technologies from the start.