Operational Technology (OT) is different from traditional Information technology (IT), as OT focuses on real time monitoring and processing with high level for Automation and Robotics and use of specific hardware and software, and dependence on sensors and other devices to gather data from the production.
Definition defined by Gartner
“Operational technology (OT) is hardware and software that detects or causes a change, through the direct monitoring and/or control of industrial equipment, assets, processes and events”.
History and Evolution of OT
In the early days of OT evaluation, most of the industries system were operated independent or Isolated ways, but along with technology enhancement, system were interconnected and inter-dependent to complete a process or product manufacturing process. For intercommunicate within devices there are multiple industrial protocols has been developed such as, Modbus, Profibus, CANbus, DNP3, BACnet etc.
Later on in when world got Internet introduced with OT, then it was easy to connect, Monitor and control the Industrial network Remotely. It was a great evaluation in the history of OT.
It will be not be wrong to say that Operational technology is utilized in many sectors and environments, such as:
- Smart factory,
- Critical manufacturing
- Transportation,
- Oil & Gas,
- Mining,
- Utility industry (electricity, water) and
Industrial Network Revolution ( 1.0, 2.0, 3.0 & 4.0)
There are different Industrial Network revolution from 1.0 to 4.0, Currently industries works on 4.0.
Let’s understand the difference and addition in each phase:
Industry 1.0 : This is very initial phase of Industrial revolution and machines was used for manufacturing without any automation.
Industry 2.0 : In this revolution adoption of electric power and development of assembly line were introduced which help in mass production.
Industry 3.0 : This a revolutionary period for industrial network. In this phase computerization and Automation was introduced. Also develop Programmable Logical Controller (PLC) which helps to a machine to be programmed for perform production in a automated way.
Industry 4.0 : This revolution is currently is in use with integrated with IOT, AI, ML, Big Data, Robotics for manufacturing. Its main motive to convert manufacturing factory is in Smart factories, so that factories can be more flexible to integrate with other system, improve Quality, Analysis, Automate. Its more to use sensors to get more data to analysis and easy to troubleshoot which helps to increase productivity and take real time decisions.
Benefits / Importance of OT
In production environment and manufacturing industries, Safety, Quality, productivity, time saving,reduce costs by improving energy usage, reducing waste, and minimizing downtime is very important and OT can provide all these benefits.
For Example: Suppose there are mobile handset manufacturing plant, in which daily they have some production target. OT technology help to make the process automate, fast, time saving with Quality, because there are robotics, machines which are operated by a programmable logical controller (PLC), HMI and the hardware and software which can make all process automate and help to achieve the target with a set of commands.
Improved effectiveness and productivity
With the help of automation, obviously error will be reduce, fast production, improve quality with help to improved effectiveness and productivity.
Early Safety Alerts:
OT system can detect the issue proactively and give safety Alerts,If detect in their system or machines.
Cost Saving:
By saving Energy, reduce waste, minimize downtime, increase productivity with definetly save the cost.
Helps to take productive Decision:
With the help of production report, team can analysis the production error, gap, positive points and can improve and take best decision to improve productivity.
Increased manpower Safety
Earlier people handle, Operate and Control the production manually and due to manually intervention chances of accident were high. But with the help of Automation manual intervention with Machines has been reduced and safety increased.
What’s the difference between OT, IT, IoT, and IIoT?
Industry Components
Industrial control systems (ICSs) : It is a system which control complete Factory production system or machines and give visibility and availability of production system. They are also sometimes called as supervisory control and data acquisition (SCADA) systems, distributed control systems (DCS), or programmable logic controllers (PLCs).
It is typically set of hardware and software components, including sensors, controllers, human-machine interfaces (HMIs to gather data from sensors and process that data for real-time output.
DCS (Distributed Control System):
It is a computerized solution where we can control multiple plant or factory process one console from multiple location which is distributed within a facility . It is used for Complex design and solution.
Control systems include SCADA systems (Supervisory Control and Data Acquisition):
It is a group of software applications for managing and controlling Industrial network process and production such as power plant, Water Treatment Plant (WTP), Sewerage Treatment Plant (STP)etc. It is gathering the real time data like temperature, pressure, flow rate etc based on program commanded and sensors from remote locations.
Programmable Logic Controllers (PLCs):
They are industrial computers used to control and command different production machines. In PLCs we can set a command or rules to how machine will operate. PLCs are programmable so we can customized to perform as per production requirement. PLCs are installed at remote locations so these are robust in nature.
RTUs (Remote Terminal Units):
As this is self-explanatory that it working as Remote side. These are electronics devices to control and monitor remote units. These RTU basically comprise of a microprocessor-based controller, with a communications interface, a number of input/output channels which is used to connect to sensors and actuators at end production machine or devices.
- These controllers are responsible for processing data from the sensors and sending commands to the actuators,
- communications interface is used to transmit data and commands between the RTU and a central control system.
Human-Machine Interfaces (HMI):
It is a user interface or dashboard on Machine which give controls a person to interact with machine or device locally. These are designed or programmed to provide real-time information about the status of machines and systems, and to allow user to monitor and control operations. it can be customized as well and these are basically a console or visual screen to manage manufacturing machines.
They typically display data in a visual format, such as graphs, charts, and alarms, and provide users with the ability to input commands and parameters.
FAQ
Q: What is OT?
A: OT stands for Operational Technology. IT is hardware and software that detects or causes a change, through the direct monitoring and/or control of industrial equipment, assets, processes and events.
Q: What is the difference between OT and IT?
A: OT is more about control and automation of physical systems and devices in factory environment, while IT is more focused on the management and storage of digital data.
Q: What are some examples of OT systems?
A: Examples of OT systems include industrial control systems, building automation systems, and energy management systems.
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