Zero Unplanned Downtime: Unified OT/IT Visibility Across 3 Production Sites
A European manufacturing group operating 3 plants with 400+ OT devices and legacy SCADA systems unified operational and IT network management into a single platform, eliminating configuration-related production stops and gaining full change traceability.
The Challenge
Production lines that cannot stop, protocols that IT tools ignore, and isolated segments that remain invisible.
OT/IT Convergence Gap
Production networks running Modbus and PROFINET existed in complete isolation from corporate IT. No unified inventory, no shared visibility, and two separate teams with no common tooling, creating blind spots that persisted for years.
Legacy Industrial Protocols
Critical PLCs and SCADA systems communicated over Modbus TCP/RTU and PROFINET. Standard IT management tools had zero visibility into these protocols, and the OT team relied on vendor-specific consoles with no export or integration capabilities.
Isolated Production Segments
Safety-critical production cells were physically isolated with no connectivity to the corporate network. Configuration changes required on-site visits with USB drives, and there was no backup or version history for any production switch or PLC gateway.
Safety-Critical Change Risk
An unauthorized switch configuration change on a bottling line caused a 4-hour production stop costing EUR 180,000. There was no change approval workflow, no rollback capability, and no way to determine which engineer made the change.
The Solution
A single platform that bridges OT and IT, works in fully isolated environments with no cloud dependencies, and makes every change traceable.
Unified OT/IT Asset Inventory
CMDB discovery scanned both IT and OT networks across all 3 plants, identifying 400+ OT devices alongside existing IT assets. Each device is tagged with its production zone, criticality level, and protocol type for unified visibility.
Offline-Capable Backup
Automated configuration backups run locally within each production zone, storing version history on-premises. Isolated segments use local collectors that sync when maintenance windows allow temporary connectivity.
Full Change Traceability
Every configuration change is logged with operator identity, timestamp, before/after diff, and approval status. The bastion enforces change approval workflows, no engineer can modify a production switch without documented authorization.
Production Zone Topology
Auto-generated topology maps show OT and IT interconnections per plant, including production zone boundaries and isolated segments. Engineers can visualize the blast radius of any change before making it.
Results & Impact
Unplanned downtime from config changes
OT asset visibility across 3 plants
Cloud dependencies, works fully offline
Change history with operator traceability
Key Platform Features Used
CMDB
Unified OT/IT device discovery with production zone tagging and protocol classification.
Configuration Backup
Offline-capable automated backups with local collectors and on-premises version history.
Topology Mapping
Per-plant topology maps showing OT/IT interconnections and production zone boundaries.
Bastion
Enforced change approval workflows with session recording for safety-critical OT devices.
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