We help manufacturers to further improve production by bridging Operation Technology (OT) and Information Technology (IT). We enable the use of all operation and production data in RAW or Edge-processed format to seamlessly integrate to IT systems (IT/OT convergence) We do this together with you and our partners.
This integration connects advanced IT—like data processing, simulation, analytics, and enterprise software with OT, the hardware and software used to design, monitor and control industrial processes. By bridging these domains, organizations can enable smarter, data-driven decision-making and achieve greater operational efficiency. This creates the foundation for smart factories.
Validate decisions before implementation
Digital or virtual twins are central to IT/OT integration, serving as virtual representations of physical objects, processes, or systems. With our partners, manufacturers can create a comprehensive solution to simulate, validate, and optimize production processes before investing in physical equipment.
Four phases of seamless integration
1. Design a flexible production line
-
Optimize plant layouts and equipment behavior with realistic simulations.
-
Use open standards that support complete interoperability within a factory, and benefit from real-time connectivity with sensors and devices.
-
Analyze data in real-world scenarios.
2. Validate the line virtually
-
Test machine behavior using OMRON’s Sysmac Studio and virtual PLCs.
-
Ensure smooth workflows with early identification of errors and bottlenecks.
-
Use connected devices and protocols to simulate real-world scenarios.
3. Manage operations & maintenance
-
Automate tasks with MES solutions for real-time production monitoring.
-
Use augmented reality for efficient maintenance and troubleshooting.
4. Leverage data for predictive maintenance
-
Collect and analyse field data via connected devices for proactive issue detection and reduced downtime.
-
Implement AI-driven insights.
Benefits of IT/OT convergence
- Enhanced efficiency: Plan, test, and optimize production lines with virtualization and 3D simulation.
- Reduced downtime: Identify issues before they occur with predictive analytics.
- Flexibility: Seamlessly integrate automation and robotics to adapt workflows for flexible manufacturing.
- Sustainability: Minimize waste and energy consumption.
Discover our comprehensive product portfolio
OMRON’s comprehensive product portfolio seamlessly connects every layer of IT/OT integration to bring smart manufacturing to life. Our advanced vision systems, inspection solutions and sensors generate precise, real-time data, while our intelligent controllers process and act on this data. Robotics, inverters, and other motion solutions turn data into action. Meanwhile, our safety technologies provide the reliability and protection needed to keep everything running smoothly.
With OMRON and our partners, your factory’s digital and physical worlds integrate into one interconnected system, empowering you to make smarter decisions, reduce costs and risk, and drive innovation.
Customer references and related articles:
Virtual Twins in the Automotive Industry: Innovation Boost for Fuel Cell Production
Three companies, one goal: OMRON, Dassault Systèmes and VAF GmbH use virtual twins to make manufacturing more flexible and sustainable.
Digitalization in the automotive industry: Seven tips for smart production
02 November, 2022 Environmental mobility requires new digitalization and intralogistics approaches. Technology partnerships help to become more efficient.
Taking the first steps to successful digitalisation
12 November, 2024 Building a digital factory isn’t an end or a reason in itself. A digital factory is a tool that gives manufacturing businesses the flexibility to respond to changes in the market - whether that is innovation trends or cost increases, and whether they are operating in the food & beverage, personal care, pharmaceutical or automotive sector.