Introduction
Modern manufacturing floors run on a layered stack of OT systems — from PLCs and SCADA controllers to machine monitoring platforms and IIoT gateways — and choosing the right ones directly determines whether a facility runs at peak efficiency or faces costly downtime and security exposure. The numbers make that exposure concrete: ransomware attacks against industrial organizations surged 87% in 2024, with manufacturers accounting for more than 50% of all observed victims.
That threat is compounding an already difficult balancing act: optimizing production output while protecting interconnected shop floor systems as IT and OT environments converge. Sixty-two percent of manufacturing victims paid ransoms in 2024 to recover operational data — even when backups existed — because stopping the line was simply not an option.
This guide breaks down the core OT systems running modern manufacturing operations, what each one does, and how to evaluate them against both performance and security requirements.
TL;DR
- OT systems monitor and control physical production through PLCs, SCADA, DCS, HMIs, and IIoT platforms
- Strong OT systems defend industrial networks from cyber threats while boosting machine performance through real-time visibility
- Key selection criteria: legacy compatibility, IT/OT integration depth, real-time monitoring, and vendor support
- Top platforms cover industrial automation (Siemens SIMATIC), OT security (Dragos), IIoT connectivity (Excellerant, PTC ThingWorx), and performance management (Honeywell Forge)
What Are OT Systems in Modern Manufacturing?
Operational Technology (OT) refers to hardware and software that interact directly with physical manufacturing processes. Gartner defines it as "hardware and software that detects or causes a change, through the direct monitoring and/or control of industrial equipment, assets, processes and events."
Core OT components include:
- PLCs (Programmable Logic Controllers) — automate discrete machine functions
- SCADA systems — monitor and control distributed industrial processes
- DCS (Distributed Control Systems) — manage complex, continuous production environments
- HMIs (Human-Machine Interfaces) — provide operator visibility and control
- Machine networking platforms — connect equipment to broader data infrastructure
This distinguishes OT from IT systems, which handle data, communications, and business applications rather than controlling physical equipment.
The IT/OT Convergence Reality
As manufacturers connect shop floor machines to ERP systems, cloud platforms, and enterprise dashboards, traditionally isolated OT systems now form part of a broader digital network. This convergence expands both capability and vulnerability. However, adoption remains in early stages — BCG reports that converged technology adoption for greenfield projects currently sits at around 10%, though it's expected to reach 50% within five years.
The global OT market reflects this growing integration. Valued at $210 billion in 2024, the market is projected to reach $364 billion by 2030, growing at a CAGR of 9.6%. The OT security segment alone is forecast to grow from $23.47 billion in 2025 to $50.29 billion by 2030. For manufacturers, that growth signals a clear shift: OT selection now carries the same weight as any major capital investment decision.
Top OT Systems for Manufacturing: Security and Optimization
These five systems were selected because they each address a distinct layer of the manufacturing OT stack — from floor-level machine control to enterprise-wide visibility and cyber defense.
Siemens SIMATIC
Siemens SIMATIC is one of the most widely deployed industrial automation and control platforms in the world, managing PLCs, drives, and HMIs across complex production lines in both discrete and process manufacturing. Its footprint spans automotive assembly lines, aerospace component fabrication, and chemical processing — environments where downtime is measured in millions, not minutes.
Key differentiators:
- Deep integration across the Siemens automation ecosystem through the TIA Portal engineering framework
- Broad protocol support including MQTT, REST, and OPC UA for cloud and enterprise connectivity
- Scalability from single-machine deployments to multi-plant operations
- Long track record in regulated industries requiring stringent compliance
- Named a Leader in the IDC MarketScape for Manufacturing Execution Systems 2024-2025
The SIMATIC S7-1500 and S7-1200 controllers now support cloud connectivity via standard MQTT protocol, while the Industrial Edge architecture facilitates seamless data exchange with SCADA, MES, and cloud services like AWS or Azure.
| Key Focus | Industrial automation and process control |
|---|---|
| Best For | Large-scale manufacturers with complex, multi-machine production environments |
| Notable Capability | Unified controller-to-cloud architecture with TIA Portal integration |
Honeywell Forge
Honeywell Forge is an enterprise OT performance management and cybersecurity platform built for process-heavy industries — oil and gas, chemicals, and discrete manufacturing. It directly addresses the dual challenge most process operators face: keeping plants running efficiently while defending against OT-targeted attacks that can trigger physical consequences as well as financial ones.
Key differentiators:
- AI-driven anomaly detection through behavioral analytics
- Unified IT/OT visibility dashboard centralizing data from disparate systems
- Strong regulatory compliance support for critical infrastructure operators
- Production Intelligence module that discovers and prioritizes key patterns, root causes, and recommended actions
- Cyber Proactive Defense solution utilizing AI to detect anomalies in OT cyber behavior
The platform enables early anomaly detection and abnormal situation prediction, maximizing plant throughput while reducing operational deviations through real-time stakeholder collaboration.
| Key Focus | OT performance management and industrial cybersecurity |
|---|---|
| Best For | Process manufacturers and critical infrastructure operators |
| Notable Capability | Unified visibility across IT and OT with AI-assisted threat detection |
Dragos
Dragos is a purpose-built OT/ICS cybersecurity platform with some of the deepest industrial threat intelligence available — covering manufacturers, utilities, and critical infrastructure operators. Where general-purpose security tools fall short, Dragos focuses exclusively on ICS environments where a mishandled security response can halt a production line or trigger a safety event.
Key differentiators:
- Proprietary industrial threat intelligence from Dragos WorldView, providing in-depth analysis and defensive recommendations
- Passive asset discovery that doesn't disrupt production processes
- Specialized expertise in ICS-specific attack vectors such as ransomware targeting SCADA and DCS environments
- Named a Leader in the 2025 Gartner Magic Quadrant for CPS Protection Platforms
- Highest scores for Threat and Anomaly Detection in the Forrester OT Security Wave
Dragos tracks 23 distinct threat groups targeting industrial sectors, with 9 active in 2024. The platform's OT-native network visibility and monitoring methodology identifies assets and threats without active scanning that could disrupt sensitive industrial processes.
| Key Focus | OT/ICS threat detection and incident response |
|---|---|
| Best For | Manufacturers prioritizing security of industrial control systems |
| Notable Capability | Industrial-specific threat intelligence and behavioral detection for OT protocols |
PTC ThingWorx
PTC ThingWorx is a leading Industrial IoT platform that lets manufacturers connect machines, collect real-time operational data, and build analytics dashboards and workflow automation apps across the shop floor. It handles connectivity across disparate industrial devices — from older equipment with limited protocol support to modern PLCs — without requiring deep infrastructure expertise.
Key differentiators:
- Flexible integration with a wide range of machines and control systems
- Strong augmented reality (AR) capabilities through Vuforia integration for maintenance and training
- Robust developer ecosystem enabling custom IIoT application development without deep infrastructure expertise
- Recognized as an Outright Leader in 2023 SPARK Matrix for IIoT Platforms
- 4.5-star rating on Gartner Peer Insights based on 129 reviews
ThingWorx's AR integration — powered by Vuforia — lets technicians overlay digital schematics and step-by-step guidance onto physical equipment, cutting lookup time and reducing errors during maintenance and repair.
| Key Focus | IIoT connectivity and industrial application development |
|---|---|
| Best For | Mid-to-large manufacturers building custom IIoT workflows and analytics |
| Notable Capability | Rapid IIoT app development with built-in AR and predictive analytics tools |
Excellerant
Excellerant is a machine tool networking and IIoT platform built specifically for CNC-driven manufacturing environments. It delivers wireless DNC connectivity, real-time machine monitoring, and shop floor data collection that feeds directly into ERP and MES systems — serving machine shops, aerospace manufacturers, defense contractors, and medical device makers across the U.S. and Canada.
Key differentiators:
- Over 30 years of machine tool networking experience spanning from Macdac Engineering (1991) through WireFreeCNC to today's Excellerant solutions
- Universal machine connectivity supporting any brand, age, or protocol — including legacy equipment with RS-232 serial connections
- Wireless DNC technology pioneered in-house, featured on the front cover of Modern Machine Shop in 2006
- Unlimited client access with no additional licensing fees — no per-seat, per-machine, or per-user restrictions
- USA-based support team that understands shop floor operations, not just IT infrastructure
- Integrated one-click revision compare for CNC programs, simplifying version control and file management
The platform supports dozens of protocols including MTConnect, OPC UA, Fanuc Focas, HAAS MNET, and Mazak Mazatrol, with Open API integration for SAP, Oracle, and other enterprise systems. Excellerant's browser-based architecture requires zero client installations, enabling deployment across PC, Mac, mobile devices, and tablets with touch-accessible interfaces.
| Key Focus | Machine tool networking, DNC, and real-time shop floor monitoring |
|---|---|
| Best For | CNC machine shops and manufacturers with mixed fleets of legacy and modern equipment |
| Notable Capability | Universal machine connectivity with wireless DNC and integrated one-click revision compare for CNC programs |
How We Chose These OT Systems
These systems were assessed based on their ability to address real manufacturing challenges — legacy compatibility, IT/OT integration depth, real-time visibility, scalability across facility sizes, and vendor credibility in industrial environments. The most common mistake manufacturers make is selecting OT platforms based on name recognition alone, without validating fit for their specific machine mix or operational maturity level.
Four Selection Factors
Protocol and machine compatibility — Manufacturers with decades-old equipment need platforms that handle both modern ethernet-connected machines and older serial-protocol devices. The median age of CNC machine tools in U.S. job shops is 7 years, with many facilities running equipment 15+ years old. MTConnect, now used on over 250,000 devices worldwide, bridges much of that gap.
Real-time visibility and alerting — Effective platforms surface part counts, cycle times, downtime reasons, OEE calculations, and actual-versus-expected output in real time. Rapid alerting stops issues before they cascade into costly stoppages.
Cybersecurity features or integrations — Manufacturing accounted for 70% of ransomware incidents hitting industrial organizations in 2023. OT platforms need native capabilities — threat detection, network segmentation, access controls — or tight integrations with dedicated OT security tools.
Proven deployment in comparable environments — Case studies and analyst recognition from aerospace, defense, or medical manufacturing validate that a platform can meet the reliability and compliance demands of critical operations.
No Single System Does Everything
No single OT system addresses every layer of the manufacturing stack. Before evaluating vendors, identify which layer you actually need to solve:
- Control layer — PLCs, SCADA systems
- Visibility and monitoring — IIoT platforms, machine monitoring, OEE analytics
- Security — Threat detection, incident response, network segmentation
- Connectivity — DNC software, protocol translation, legacy machine integration
Match the tool to that need — not the other way around.
Conclusion
The best OT system for a manufacturing facility is the one that aligns with that facility's specific operational architecture — whether that means securing a SCADA-heavy process environment, gaining visibility into a mixed CNC machine fleet, or connecting legacy equipment to modern ERP workflows. The convergence of IT and OT creates both opportunity and risk, making platform selection a strategic decision that impacts both operational efficiency and cyber resilience.
Before committing to a platform, evaluate it against your long-term roadmap, not just current requirements. Key factors to assess:
- Scalability: Can it accommodate additional machines, facilities, or production lines without costly rework?
- Vendor support: Is ongoing technical support available, and what does the support model look like post-implementation?
- Total cost of ownership: Does the licensing structure remain predictable as your operations grow?
- Protocol and integration coverage: Will it support future equipment alongside your existing mix?
For manufacturers looking to start with machine connectivity and real-time shop floor visibility, Excellerant's IIoT platform offers a simplified, proven entry point. With 30 years of machine tool networking expertise and support for any machine, any protocol, new or legacy — the platform eliminates the complexity typically associated with Industry 4.0 implementation. The USA-based support team understands shop floor operations and can guide integration with your specific equipment mix and ERP systems. Schedule a free demo to discuss your facility's integration needs and see how Excellerant can get your machines connected and producing actionable data.
Frequently Asked Questions
What is an OT system in manufacturing?
OT (Operational Technology) systems are the hardware and software used to monitor and control physical manufacturing processes — including PLCs, SCADA systems, DCS, HMIs, and machine networking platforms. Unlike IT systems that manage data or business processes, OT systems interact directly with physical equipment to control production operations.
What is the difference between IT and OT systems in a manufacturing environment?
IT systems handle business data, communications, and enterprise applications like ERP and email, while OT systems control physical machinery and production processes on the shop floor. As manufacturers connect shop floor data to cloud and business systems, the two are converging — creating efficiency gains alongside new security challenges around network segmentation and access controls.
How do OT systems help optimize manufacturing operations?
OT systems give manufacturers real-time visibility into machine performance, enabling predictive maintenance, reducing unplanned downtime, and improving production scheduling. By connecting shop floor data to ERP and planning systems, they eliminate information lag and allow proactive adjustments before issues affect delivery.
What are the biggest cybersecurity risks facing OT systems in manufacturing?
The primary risks include ransomware targeting ICS/SCADA systems (up 87% in 2024), lateral movement from compromised IT networks into OT environments, legacy devices with no native security, and weak segmentation between corporate and production networks. In 2024, 22% of OT vulnerabilities were network exploitable and perimeter-facing — making initial access easier for attackers.
Can legacy CNC machines be connected to modern OT and IIoT platforms?
Yes. Machine tool networking solutions support multiple protocols — MTConnect, serial communications, and PLC intermediary devices — allowing legacy equipment to integrate without replacement. This matters because many facilities run CNC machines 15+ years old; platforms like Excellerant are built specifically to connect both legacy and modern equipment.
What should manufacturers prioritize when selecting an OT system?
Focus on compatibility with your existing machines and controls, depth of real-time visibility, IT/OT integration capability, scalability, vendor support quality, and total cost of ownership. Most importantly, match the platform to your actual need — whether that's control-layer automation, monitoring, security, or connectivity.
