Quadruple Automation Services
Solutions PLC & SCADA Systems IT/OT Convergence
ISA-95 • IEC 62443 • OPC-UA • MQTT Sparkplug B

Unified IT & OT.
One Connected
Smart Factory.

QAS bridges enterprise IT systems and industrial OT layers into a secure, real-time and unified architecture — connecting ERP, MES, SCADA, PLCs and IIoT devices through a standardised data backbone.

Get IT/OT Assessment Free Architecture Review
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Data Latency
ISA-95
Standard
IEC 62443
Security
15+
Protocols
What Is IT/OT Convergence?

Two Worlds.
One Unified Architecture.

OT (Operational Technology) — PLCs, SCADA, DCS, sensors and machines on the shop floor — has traditionally operated in isolation. IT (Information Technology) — ERP, MES, databases and enterprise applications — lived in a completely separate world.

IT/OT Convergence breaks down this barrier. QAS designs and implements the middleware, protocols, network architecture and data models that allow these two layers to communicate seamlessly, securely and in real time.

The result: a single source of truth from sensor to boardroom — enabling better decisions, faster responses and full operational visibility.

🏭

OT Layer

PLCs, SCADA, HMI, DCS, sensors, actuators and robots on the factory floor.

💻

IT Layer

ERP, MES, databases, analytics platforms and enterprise applications.

🔀

Convergence Layer

OPC-UA, MQTT, middleware and data brokers that bridge both worlds securely.

📊

Unified Data

One consistent data model across all layers — from sensor reading to ERP posting.

What We Deliver

Core IT/OT Capabilities

End-to-end convergence services — from architecture design to live production deployment

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Network Architecture & Segmentation

Designing secure network zones — DMZ between IT and OT, IDMZ (Industrial DMZ), Purdue model segmentation and firewall rules that allow data to flow without exposing OT assets to IT threats.

Purdue Model Design IDMZ Implementation Firewall Rule Sets VLAN Segmentation IEC 62443 Compliance Network Redundancy
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Protocol Normalisation

Translating between dozens of industrial protocols — Modbus, Profinet, EtherNet/IP, OPC-DA — into modern standards like OPC-UA and MQTT Sparkplug B that IT systems can consume natively.

OPC-UA Server/Client MQTT Sparkplug B Modbus TCP/RTU Profinet & EtherNet/IP OPC-DA to OPC-UA Bridge REST API Adapters
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Unified Namespace (UNS)

Implementing a Unified Namespace using MQTT brokers (HiveMQ, EMQX) or N3uron as the central data hub — one consistent hierarchical topic structure that all systems publish to and subscribe from.

MQTT Broker Setup N3uron UNS Sparkplug B Payloads ISA-95 Topic Structure Pub/Sub Architecture Real-time Data Fabric
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OT Cybersecurity

Protecting OT environments from cyber threats without disrupting production — IEC 62443 risk assessments, patch management strategies, anomaly detection and secure remote access solutions.

IEC 62443 Assessment OT Asset Inventory Anomaly Detection Secure Remote Access Patch Management Incident Response Plan
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Edge Computing & Data Aggregation

Deploying edge gateways (Ignition Edge, N3uron, industrial PCs) at the machine level to pre-process, filter and buffer data locally before forwarding to cloud or on-premise systems.

Ignition Edge Gateway N3uron Edge Nodes Local Data Buffering Store & Forward Edge Analytics Cloud Push (Azure/AWS)
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Cloud & On-Premise Integration

Connecting factory floor data to Azure IoT Hub, AWS IoT Core, on-premise historians or custom cloud platforms — with secure TLS encryption, certificate-based authentication and data governance.

Azure IoT Hub AWS IoT Core InfluxDB / TimescaleDB Secure TLS Tunnels Certificate Auth Data Governance
Tech Stack

Technologies We Deploy

Industry-proven platforms across every layer of the convergence stack

Connectivity & Protocols

  • OPC-UA
  • MQTT Sparkplug B
  • Modbus TCP
  • Profinet
  • EtherNet/IP
  • OPC-DA
  • REST / SOAP APIs
  • MTConnect

Edge & IIoT Platforms

  • Ignition Edge
  • N3uron
  • Kepware
  • Azure IoT Edge
  • AWS Greengrass
  • Node-RED
  • HiveMQ Broker
  • EMQX Broker

Security & Network

  • Cisco Industrial
  • Fortinet OT
  • Claroty
  • Dragos
  • Nozomi Networks
  • Tofino Firewall
  • VPN / Secure Tunnel
  • IEC 62443

Data & Analytics

  • InfluxDB
  • TimescaleDB
  • Azure IoT Hub
  • AWS IoT Core
  • Grafana
  • Power BI
  • Ignition Historian
  • OSIsoft PI
The Difference

Before vs After Convergence

Scenario
Without Convergence
With IT/OT Convergence
Data Access
Engineers walk to the machine room or use USB sticks to retrieve PLC data.
Any authorised user accesses live machine data from any device, anywhere, securely.
Production Visibility
ERP shows orders as open. No one knows real WIP status until a supervisor checks manually.
Real-time production status flows from PLC → MES → ERP automatically. Full WIP visibility.
Incident Response
Alarm on the shop floor takes minutes to reach the right person. Root cause unclear.
Alarm triggers automated notification chain. Historian data available instantly for analysis.
Cybersecurity
OT network flat and unsegmented. IT and OT on same VLAN. Any breach affects everything.
Network segmented by ISA-95 zones. IDMZ controls all IT↔OT traffic. OT assets fully protected.
Data Silos
Machine data stuck in historian. ERP data stuck in SAP. No correlation possible.
Unified Namespace connects all systems. Cross-layer analytics available in real time.
Maintenance
Reactive maintenance. Equipment fails → production stops → engineer investigates.
Sensor data feeds predictive models. Maintenance triggered before failure. Zero unplanned stops.
Our Approach

How We Converge Your IT & OT

A structured, non-disruptive methodology that protects your existing OT investments

01

Assessment & Discovery

2–3 Weeks

Map every OT asset, protocol and network segment. Identify IT systems and integration requirements. Produce a convergence gap analysis and risk assessment.

OT Asset Discovery Protocol Audit Network Mapping Security Assessment Gap Analysis
02

Architecture Design

2–4 Weeks

Design the target IT/OT architecture — network zones, IDMZ layout, protocol translation strategy, Unified Namespace structure and data model aligned to ISA-95.

Network Zone Design IDMZ Blueprint UNS Data Model Protocol Mapping Security Architecture
03

Pilot Implementation

4–8 Weeks

Deploy convergence infrastructure for one production line or area. Prove the architecture works, tune performance and validate security before full rollout.

Pilot Line Selection Edge Gateway Deploy Protocol Bridge Setup UNS Commissioning Security Validation
04

Full Rollout & Go-Live

8–16 Weeks

Extend the converged architecture to all lines and sites. Connect to ERP, MES and analytics platforms. Train operations and IT teams on the new unified environment.

Site-Wide Rollout ERP/MES Integration Analytics Connection Team Training Go-Live Support
Start Your IT/OT Convergence Journey

Ready to Connect Your Factory?

Book a free architecture review. Our engineers will assess your current IT and OT landscape and design a convergence roadmap tailored to your factory.

Book Architecture Review Free Assessment
ISA-95 Certified Architecture
IEC 62443 Security
15+ Protocols Supported
Non-Disruptive Implementation
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