IT/OT Integration Consulting:
connect your plant with management

The problem we solve

In most industrial plants there is a critical gap between two worlds: the OT network (Operational Technology), where PLCs, sensors and SCADA live, and the corporate IT network, home to the ERP, Power BI and management systems. Both worlds generate valuable data but rarely talk to each other.

The result is predictable: managers make production decisions based on manual reports that are hours or days old, while the real data is available in real time on the control equipment — but nobody sees it.

What exactly do we do?

Our IT/OT Integration consulting is a turnkey service that connects your industrial control equipment with the analysis and management platforms your company already uses. The result: real-time production data available to every level of the organization.

The typical scope of a project includes:

• OT asset survey — a complete inventory of PLCs, available protocols and relevant variables
• IT/OT architecture design — definition of the technical solution while respecting network segmentation
• Implementation of the integration stack — Node-RED, OPC UA, MQTT as appropriate
• Industrial Historian — a time series database (InfluxDB) for complete history
• Dashboards and reports — Grafana for the control room, Power BI for management
• Team training — your staff operate and maintain the solution on their own

The architecture we implement

We use exclusively open technologies with no proprietary licenses. This means you are not tied to any vendor and can grow or modify the solution with any integrator in the future.

The architecture is designed to respect IT/OT segmentation: PLCs are never directly exposed to the corporate network. An intermediary server (edge or cloud, as you prefer) acts as a secure bridge between both networks.

Our consulting process

Phase 1 — Assessment (1 week)

We visit your plant, build the inventory of OT equipment, identify the available data and define the KPIs that management needs to see. At the end of this phase you have an architecture document with a detailed scope and budget.

Phase 2 — Implementation (2 to 6 weeks)

We install and configure the complete stack. We work in parallel with production — no planned shutdowns. Implementation is done in stages, prioritizing the most critical lines or equipment first.

Phase 3 — Dashboards and reports (1 to 2 weeks)

We build the operational dashboards (Grafana) and executive reports (Power BI) together with your team, to make sure they show exactly what each level of the organization needs to see.

Phase 4 — Training and handover (1 week)

We train the system administrators so they can add new variables, create new dashboards and maintain the platform on their own. We deliver complete technical documentation.

Real cases

AJAY SQM — Chemical industry, Chile

Fatek PLCs with Modbus protocol, LoRaWAN sensors spread across the field and a requirement for reporting to the board. We implemented Node-RED as middleware, InfluxDB as the Historian and Grafana + Power BI for visualization. Chemical process data reached the executive dashboard in real time for the first time in the plant's history.

Aislapol — Manufacturing, Chile

A plant information system with real-time OEE, energy indicators and Power BI integration for automatic reports to management. No proprietary licenses. The production team cut report preparation time from 4 hours a week to zero — the report generates itself.

CMPC Papeles — Paper industry, Chile

Migration from a proprietary system (PI System) to an open architecture. Elimination of costly annual licenses, OPC UA integration with multiple production lines and a solid foundation for advanced analytics. ROI calculated at under 18 months from license savings alone.

Who is this consulting for?

Our IT/OT integration consulting is designed for industrial plants that:

• Have PLCs and control systems running but no real-time data visibility
• Produce production reports manually or semi-manually
• Want to connect their plant data with Power BI, SAP ERP or corporate systems
• Have evaluated proprietary solutions but found the licensing cost prohibitive
• Have equipment from different brands and need a vendor-independent solution

Investment and typical ROI

The cost of an IT/OT integration project varies with the amount of equipment, the complexity of the network and the number of KPIs to calculate. A pilot project for one production line can be ready in 4 weeks with an investment within reach of mid-sized companies.

ROI comes mainly from three sources: less time spent preparing reports (typically 3-8 hours a week per analyst), faster, more accurate decisions based on real data, and early detection of production problems before they escalate.