IT/OT-Infrastruktur
Also: IT/OT, IT-OT-Integration, OT-Infrastruktur, IT/OT-Konvergenz, Operational Technology, IT-OT-Architektur
AI-generated
IT/OT infrastructure refers to the combined technical foundation of enterprise-wide information technology (IT) and operational technology (OT), including controllers, sensors, and equipment.
Key facts
- IT/OT infrastructure connects corporate IT (ERP, WMS, cloud) with operational technology (PLCs, conveyor systems, sensors) into a seamless data network.
- OT systems typically have longer patching and maintenance cycles than IT systems, requiring a separate security strategy for each segment.
- Clear network separation between IT and OT — for example, through DMZ zones — is an established standard in logistics automation.
- Without defined operational responsibility for IT/OT interfaces, grey areas emerge that can lead to extended downtime in the event of a disruption.
- Scalability of the IT/OT architecture is critical, as automation projects in logistics facilities are frequently implemented in multiple expansion phases.
What is IT/OT infrastructure?
IT/OT infrastructure describes the overall technical architecture that connects information systems (IT) with operational technology (OT). The IT side includes servers, networks, ERP and WMS systems, and cloud services. The OT side encompasses programmable logic controllers (PLCs), drive systems, conveyor technology, sensors, and actuators. Traditionally, these two worlds were organizationally and physically separate: IT fell under the responsibility of corporate IT, while OT was managed by plant or facility management. However, with increasing automation and the deployment of AGVs, AutoStore systems, or fully automated small-parts warehouses, a close exchange of data has emerged that requires a unified infrastructure strategy.
How does IT/OT integration work in practice?
In modern logistics facilities, OT components communicate with higher-level IT systems via industrial protocols (e.g., OPC-UA, MQTT, or proprietary interfaces). A warehouse management system receives status data from conveyor systems, an ERP system passes orders to control software, and sensor data from conveyor technology flows into dashboards for operations management. Physical network separation — for example, through DMZ zones or dedicated OT segments — is standard practice, as OT systems often have different availability and patching cycles than IT systems. A failure in the OT layer directly impacts material flow, while an IT failure primarily affects transactional processes. Redundancy and failover concepts must therefore be designed separately for each layer.
Typical integration scenarios include:
- Connecting conveyor system PLCs to the WMS via middleware or a material flow controller (MFC)
- Real-time transmission of picking data from data capture terminals and radio frequency terminals to ERP and WMS
- Remote diagnostics and predictive maintenance using sensor data from OT equipment, evaluated in cloud-based analytics environments
- Secure remote maintenance access for equipment vendors via isolated network segments
What matters when selecting and planning?
When planning an IT/OT infrastructure for logistics facilities, several dimensions should be considered. First, network architecture: are OT networks physically or logically separated from corporate IT? What handoff points exist, and who is responsible for firewall rules? Second, security strategy: OT systems often run on outdated operating systems with long patching intervals, because maintenance windows are rare. An IT security concept must account for these realities. Third, operational responsibility: whether IT and OT teams operate jointly or separately significantly affects escalation processes and response times during incidents. Depending on the vendor, responsibility for interfaces between the material flow controller and the WMS may also vary — this should be clearly defined contractually. Fourth, scalability: automation projects often grow in phases; the infrastructure must be able to accommodate new equipment without requiring a complete overhaul.
Related terms
- AGV
AGV (Automated Guided Vehicle) refers to driverless transport vehicles that automatically move goods in warehouses and production environments. They follow predefined or sensor-controlled routes without a human driver.
- AMR
AMR (Autonomous Mobile Robot) is a driverless, self-navigating transport robot that moves goods within a warehouse without any fixed installed infrastructure. It orientates itself independently using sensors and digital maps, and dynamically avoids obstacles.
- API
An API (Application Programming Interface) is a defined interface through which two software systems can exchange data in an automated and standardized way. In intralogistics, it connects systems such as WMS, ERP, or TMS with one another and with external services.
- Aktuator
An actuator is a technical component that converts electrical, pneumatic, or hydraulic control signals into mechanical movement or force. In intralogistics, actuators control conveyor belts, diverters, grippers, and lifting elements in automated systems.
- AutoStore
AutoStore is a cube-based automated storage system in which driverless robots traverse an aluminum grid to stack plastic bins and retrieve them on demand for delivery to picking ports. The system is considered one of the most space-efficient automated small-parts warehouses available for standardized bin-compatible goods.
- Automatisches Kleinteilelager (AKL)
The Automated Small Parts Warehouse (AKL) is a fully automated storage system for totes, trays and small parts, in which storage and retrieval operations are performed without manual intervention by stacker cranes or shuttle systems.
- Automatisierung
Automation refers to the use of technologies and systems to execute processes fully or partially without human intervention. In intralogistics, the spectrum ranges from simple conveyor systems to fully automated high-bay warehouses with autonomous vehicles.
- BDE-System
A BDE system (operational data collection system) captures machine and manual process data in real time directly at the source – such as at machines, conveyor systems, or workstations.
- BDE-Terminals
BDE terminals are stationary or mobile devices used for operational data capture, enabling employees at workstations, machines, or warehouse areas to digitally record process, time, and quantity data directly at the point of origin.
- Cloud Computing für Logistik
Cloud computing for logistics refers to the operation of logistics software and data platforms via external cloud services instead of on-premises data centers. Typical applications include warehouse management systems, transportation management systems, track-and-trace, as well as BI and integration platforms.
- Datenfunkgeräte
Data radio devices are mobile or stationary hardware components that transmit data wirelessly via radio protocols such as WLAN or cellular. In warehouse and transport environments, they form the operational interface between employees and IT systems such as WMS or ERP.
- Datenfunkterminal
A data radio terminal is a mobile device for wireless data capture and transmission in the warehouse, combining a display, input, and scanner in one unit. It typically communicates with a warehouse management system via Wi-Fi and supports processes such as goods receipt, picking, and inventory counting.