Intelligent Engineering
Our Intelligent Engineering solutions across products, plant and networks, combine our engineering expertise with advanced technologies to enable digital engineering & operations, develop autonomous products & platforms, and build sustainable energy and infrastructure
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Introduction
Risk assessment automation is enabled by an engine that include known threats, commonly known vulnerabilities, and associated risks for commonly used information assets. Approximately 70% of assets and their associated risks, vulnerabilities, and threats remain consistent across assessments, allowing automation to eliminate redundancy and improve accuracy.
Risk assessment is critical across domains such as automotive, healthcare, energy, mining, utilities. Identifying the security risks early and taking remediation actions helps reduce cyber threats. With Dynamic risks driven by evolving technologies and regulations, Gen AI enables rapid risk scoring and report generation. Reports are then reviewed to eliminate the false positives and tailor insights to the specific environment.
Why Risk Assessments Must Evolve
Risk assessment help identify security risks associated with assets across domains. They are essential for compliance with industry standards such as ISO 27001, ISO 31000, ISO 14971, and must be conducted annually or at predefined intervals.
For the automotive sector, Threat Analysis and Risk Assessment (TARA) is required to comply with ISO 21434. These assessments help determine residual risks, define security goals and derive cybersecurity requirements. In healthcare, assessments must align with ISO 14971 to meet FDA mandates. OT security assessments are guided by IEC 62443.
Cyient’s accelerator solution- CySecAssure - streamlines risk assessments by reducing manual effort and quickly generating draft reports. After analyzing the scope and environment, the drafts are reviewed and finalized. The framework leverages domain-specific ISO standards for accuracy and compliance.
TARA for a Global Automotive OEM
Cyient conducted TARA (Threat Analysis and Risk Assessment ) on an OEM’s network infrastructure and assets including plant networks, data centers, product management applications , and engineering systems. Using the automation engine, the draft report was generated quickly and finalized with minimal effort. The overall timeline was cut from 15 months to 6 months using CySecAssure.
Cloud-Based Application Risk Assessment
Risk assessment for an AWS-hosted enterprise application involved comprehensive vulnerability scanning, penetration testing, and remediation validation. Conducted in alignment with ISO 27001 standards, all critical and high-risk findings were addressed. Final reports were completed after iterative reviews, streamlined through CySecAssure.
End – to -End Cybersecurity for an Asian Automotive OEM
Vehicle-level TARA was conducted to derive security goals and security requirements. The scope also included support for security library development and integration, cybersecurity validation and penetration testing, Post-Development (production and security operations), homologation for statutory compliance, and incident and vulnerability management. The reports were generated in customer-preferred templates and submitted for UN R155/R156 certification using ISO 21434.
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Typical Integration Areas in IT/OT Convergence and its Benefits
RESOURCE MANAGEMENT
Resource management in IT/OT integration ensures efficient allocation and monitoring of assets, workforce, and operational resources across industrial environments.
Capabilities:
- Real-Time Resource Monitoring: Track workforce allocation, equipment availability, and usage through SCADA and MES systems.
- Dynamic Scheduling: Optimize work order assignments based on real-time data from OT systems integrated with IT platforms.
- Condition-Based Maintenance: Resources are allocated for preventive maintenance based on IoT sensor inputs, reducing downtime.
Use Case:
- Industry: Manufacturing
- Implementation: Using Ignition and Aveva, a factory dynamically schedules technicians to machines needing urgent maintenance based on OT system alerts. The system integrates workforce availability from the ERP module.
SAP INTEGRATION FOR BOM, FINANCE, AND WORK ORDERS
SAP's ERP modules play a critical role in bridging IT and OT layers by offering seamless integration of business processes with operational technology.
Capabilities:
- BOM (Bill of Materials):
- Real-time updates to BOM based on IoT data (e.g., detecting material shortages).
- Automatic generation of procurement requests triggered by SCADA alerts.
- Finance:
- Automated cost tracking for production batches, based on resource usage reported from MES and IoT data.
- Real-time energy cost calculations by integrating energy meters with SAP CO (Controlling).
- Work Orders:
- SCADA alerts automatically create and assign work orders in SAP PM (Plant Maintenance).
- Closed-loop feedback ensures execution updates flow back to SCADA for visibility.
Use Case:
- Industry: Energy
- Implementation: A power plant integrates Ignition with SAP PM (Plant maintenance) to automatically create work orders based on predictive maintenance analytics, reducing mean time to repair.
INVENTORY AND TOOL MANAGEMENT
Efficient inventory and tool management in IT/OT integration ensures real-time tracking of physical assets to minimize production delays and waste.
Capabilities:
- IoT for Real-Time Tracking:
- RFID and IoT sensors track inventory levels, tools, and spare parts in warehouses.
- Integrates with SCADA for alerting low stock levels.
- Predictive Stock Replenishment:
- ERP systems like SAP forecast inventory needs based on OT data trends (e.g., frequent replacement of specific machine parts).
- Tool Utilization Monitoring:
- Real-time monitoring of tool usage (e.g., wear and tear) integrated into MES systems ensures timely replacements.
Use Case:
- Industry: Aviation Maintenance
- Implementation: VT SCADA tracks the availability of calibrated tools for aircraft maintenance, integrating with SAP MM (Material Management) to trigger replenishment orders automatically.
CYBERSECURITY
Cybersecurity is critical in IT/OT integration to protect sensitive operational data, ensure continuity, and prevent breaches.
Capabilities:
- Network Segmentation:
- OT networks are segmented from IT systems, with firewalls and DMZs (Demilitarized Zones) mediating data transfer.
- Data Encryption:
- IoT data from sensors and SCADA systems is encrypted during transmission and storage.
- Access Control:
- Role-based access ensures only authorized personnel access critical OT systems.
- Multi-factor authentication (MFA) is enforced for IT/OT interfaces.
- Threat Detection and Response:
- AI-based intrusion detection systems (IDS) monitor OT networks for anomalies.
- Incident response is coordinated through integrated IT platforms.
- Compliance Standards:
- Adherence to IEC 62443, NERC CIP, and ISO/IEC 27001 for IT/OT environments.
Use Case:
- Industry: Oil and Gas
- Implementation: Aveva System Platform uses role-based access and anomaly detection to secure data pipelines between offshore rigs and cloud-based analytics.
PLM INTEGRATION
Product Lifecycle Management (PLM) integration in IT/OT environments connects the design, production, and maintenance phases of product life cycles, ensuring seamless data flow between engineering, operations, and maintenance teams.
Capabilities:
- Design and Production Data Linkage: Link CAD models, specifications, and product designs to the operational and maintenance systems.
- Real-Time Product Monitoring: Integrate data from OT sensors and systems back to PLM for real-time tracking of product performance and lifecycle status.
- Closed-Loop Feedback: Integrate production and field data into the PLM system to inform future design iterations and product improvements.
Example Use Case:
- Industry: Automotive
- Implementation: A manufacturing plant integrates its MES system with the PLM software, allowing real-time feedback from the shop floor to inform design changes, improving product quality and reducing cycle times.
Key Benefits
Case Studies
IT/OT Integration in Various Industries
IT/OT convergence has transformed multiple industries, enabling predictive maintenance, real-time decision-making, and improved operational efficiency. Below are key industry-specific use cases that highlight the impact of IT/OT integration.
Mining Industry
Real-Time Fleet
Challenge:
Mining operations suffered from unplanned downtime, inefficient fleet routing, and safety risks due to disconnected IT and OT systems.
Solution:
- IoT sensors and SCADA systems were installed on mining trucks and conveyors to track fuel consumption, engine performance, and location.
- Predictive maintenance algorithms forecasted equipment failures to prevent costly breakdowns.
- Real-time fleet tracking helped optimize dispatching and reduce idle time.
Outcome:
- 15% reduction in vehicle downtime
- 10-20% improvement in fleet efficiency
- Enhanced safety through proactive alerts
Energy Sector
Smart Grid Modernization
Challenge:
A major utility provider struggled with power outages and inefficiencies due to a lack of real-time monitoring and automation.
Solution:
- SCADA and IoT were integrated to track transformer health, power flow, and outages.
- AI-driven analytics predicted demand spikes and potential equipment failures.
- Demand response systems dynamically managed energy distribution.
Outcome:
- 25% reduction in power outages
- Improved customer satisfaction with real-time service alerts
- Lower operational costs through better grid efficiency
Manufacturing
Smart Factory Transformation
Challenge:
A leading automotive components manufacturer needed to improve efficiency, product quality, and reduce downtime.
Solution:
- Siemens Opcenter MES was integrated with IoT sensors and SCADA systems to track production metrics in real-time.
- Augmented reality (AR) for maintenance provided digital overlays for faster troubleshooting.
Outcome:
- 30% increase in production efficiency
- 15% reduction in unplanned downtime
- 10% lower defect rates with real-time quality control
Water Treatment
Intelligent Water Management
Challenge:
A global water management company faced inefficiencies due to water leaks, energy waste, and compliance issues.
Solution:
- IoT sensors were deployed for real-time water quality and pressure monitoring.
- Cloud-based analytics optimized pump operations based on consumption patterns.
- AI-powered leak detection minimized water loss.
Outcome:
- 25% reduction in water wastage
- Lower energy costs through optimized operations
- Automated compliance reporting for regulatory standards
Summary of IT/OT Integration Across Industries
IT/OT integration has become a cornerstone of digital transformation, enabling industries to enhance operational efficiency, improve decision-making, and drive innovation. By connecting Information Technology (IT) systems, which manage data and software, with Operational Technology (OT) systems that control physical equipment and processes, organizations can achieve a seamless flow of data across the enterprise. This convergence is rapidly gaining prominence in various industries and is reshaping how businesses operate.
Impact Across Industries
- Predictive Maintenance & Asset Management:
Real-time monitoring of physical assets through IoT and sensors, integrated with IT systems, enables the prediction of equipment failures before they occur, reducing downtime and extending the lifespan of assets. - Data-Driven Decision Making:
The flow of data from OT devices into IT systems allows for advanced analytics and AI-powered insights, which enhance decision-making at every level of the organization, from the shop floor to the executive suite. - Operational Flexibility & Agility:
IT/OT integration provides the flexibility to adapt to market changes or operational demands by enabling real-time adjustments. This agility is crucial in industries like manufacturing and energy, where fluctuations in supply and demand need to be addressed quickly. - Scalability & Future-Proofing:
With cloud and edge computing technologies, IT/OT integration offers scalability for businesses as they grow and adapt. Cloud solutions allow for the centralization of data from distributed OT assets, providing easier access, analysis, and integration across the organization.
Business Benefits
- Cost Reduction
IT/OT integration enables businesses to optimize resource utilization, improve asset performance, and minimize downtime. Predictive maintenance and real-time monitoring help avoid unnecessary repairs, reduce operational costs, and improve the efficiency of both workforce and equipment. These efficiencies translate into substantial cost savings across the organization.
Key Benefits: Reduced operational costs, better asset management, and minimized downtime. - Enhanced Safety
The integration of IT and OT systems allows for real-time monitoring of operations, which helps identify potential risks or faults early. This enables quicker intervention to prevent accidents, ensuring a safer work environment. Additionally, continuous monitoring of critical systems can reduce the risk of environmental harm or regulatory violations.
Key Benefits: Early hazard detection, improved workplace safety, and minimized risk of accidents or environmental impact. - Regulatory Compliance & Reporting
By automating data collection and reporting, IT/OT integration ensures that businesses remain compliant with industry standards and regulations. Accurate, real-time reporting improves auditability and transparency, reducing the risk of non-compliance and helping businesses meet regulatory requirements more efficiently.
Key Benefits: Streamlined compliance, accurate reporting, and enhanced transparency for audits. - Improved Customer Experience
Efficient operations result in higher-quality products and services, contributing to better customer satisfaction. For industries like utilities and energy, real-time monitoring helps prevent service disruptions, ensuring continuous and reliable service delivery. A seamless, reliable customer experience fosters greater trust and loyalty.
Key Benefits: Higher product quality, increased service reliability, and improved customer satisfaction.
- Improved Operational Efficiency
IT/OT integration streamlines processes by enabling real-time data exchange between IT systems and operational technology. Predictive maintenance, real-time monitoring, and dynamic scheduling help reduce downtime and optimize resource allocation, driving greater operational efficiency and cost optimization.
Key Benefits: Streamlined processes, reduced downtime, enhanced resource allocation, and better cost management. - Faster Decision-Making
With integrated IT and OT systems, decision-makers gain access to real-time insights, allowing for quicker, more informed decisions. This improved data visibility enables businesses to respond swiftly to market changes, operational challenges, and customer demands, enhancing agility.
Key Benefits: Faster, data-driven decision-making and improved responsiveness to market dynamics. - Enhanced Innovation and Competitiveness
Leveraging technologies such as IoT, AI, and digital twins through IT/OT integration accelerates innovation by providing real-time insights and new capabilities. Businesses can adapt more rapidly to evolving customer demands and market conditions, helping them stay ahead of the competition.
Key Benefits: Increased innovation, greater ability to meet market demands, and sustained competitive advantage. - Increased Security and Compliance
Robust cybersecurity measures are critical when integrating IT and OT systems. By implementing secure data transfer protocols, access controls, and compliance with industry standards, businesses can protect their critical infrastructure from cyber threats.
Key Benefits: Enhanced system security, reduced vulnerability to cyber threats, and adherence to industry regulations.
About the Author
Sreelekshmi PS
Senior Software Engineer, Cybersecurity team, Digital & Technology Group
She is a cybersecurity professional with an M.Tech in Cyber Forensics & Information Security and close to seven years of experience in the field. As a Certified Information Security Manager (CISM) and ISO 27001 Lead Auditor, she has built deep expertise in vulnerability assessments and penetration testing (VAPT), risk assessment, threat modeling, threat analysis, application security, cloud security assessment, and security audits across a wide range of products, services, and domains. Her strong foundation in Governance, Risk, and Compliance (GRC), along with hands-on experience in data privacy implementation, enables her to drive security strategies that are both effective and compliant. Sreelekshmi is well-versed in global standards and regulatory frameworks, including ISO 27001, ISO 21434, GDPR, DPDPA, CCPA, HIPAA, CSA STAR certification, as well as NIST, COBIT, ENISA, SOCI, CRA, and the EU AI Act. With a keen eye for emerging threats and a commitment to continuous learning, she consistently delivers cybersecurity solutions that support business resilience and regulatory alignment.
About the Authors
Sathish Kumar Thiagarajan is a seasoned Controls & Automation Engineer with over 18 years of global experience in managing large-scale industrial automation projects involving PLCs, SCADA, and Drives. He specializes in optimizing technical workflows, ensuring regulatory compliance, and leading cross-functional teams to deliver seamless IT/OT integration solutions. Known for enhancing operational efficiency and driving cost-effective innovations, his expertise helps shape transformative strategies in industrial automation.
Srinivasu Parupalli is an experienced Systems Engineer with expertise in program management and delivery across multiple domains, including Industry 4.0, Manufacturing, Embedded Systems, IoT, Software Applications Development, and Cloud Integrations. He has extensive experience in end-to-end product development and has been instrumental in building and training teams on emerging technologies such as Ignition, Solumina, Aveva, and SCADA systems for deployment in diverse customer projects. With a strong background in industrial automation, he has worked across various industries, including Manufacturing, Energy, Utilities, Healthcare, and Process Automation, developing MES, SCADA, and HMI solutions integrated with other applications. His expertise lies in customer engagement, requirements analysis, and risk management, ensuring the successful execution of complex automation projects.
