From German precision engineering to Indian auto manufacturing to US industrial IoT. OT/IT convergence, predictive maintenance AI, and factory-floor security. Reduce unplanned downtime, secure critical infrastructure, and enable smart factories.
Manufacturing IT
Bridging the factory floor and the server room globally
Modern manufacturers across Germany, India, and the US face the challenge of converging operational technology with IT infrastructure without compromising production uptime. Sentos provides OT/IT security, predictive maintenance intelligence, and legacy system modernisation tailored for mid-market manufacturers worldwide, from precision engineering to automotive to industrial IoT.
- OT/IT convergence security with network segmentation (IEC 62443 aligned)
- Predictive maintenance AI to reduce unplanned downtime by 60%+
- Legacy system modernisation without production disruption
- Smart factory enablement with supply chain visibility
Industry Challenges
When the factory floor meets the server room
Unplanned downtime is extremely expensive
A single production line outage can cost $6,000–18,000 USD per hour. Most manufacturers rely on reactive maintenance, discovering failures only after the line stops.
OT/IT convergence creates blind spots
As factory-floor SCADA, PLCs, and IoT sensors connect to the corporate network, the attack surface explodes. Most IT teams lack visibility into operational technology assets.
Legacy systems resist modernisation
ERP systems, MES platforms, and custom SCADA implementations are decades old. They can't integrate with modern analytics, cloud platforms, or AI tools — but replacing them risks production disruption.
How Sentos Helps
Industry 4.0 ready — without the risk
Unplanned downtime is extremely expensive
SentosIQ predictive maintenance & 24/7 monitoring
SentosIQ monitors server and network health across your plant floor, predicts hardware failures 72 hours ahead, and auto-creates maintenance tickets before production is impacted.
OT/IT convergence creates blind spots
Network segmentation & OT-aware security monitoring
We design and implement network segmentation between IT and OT zones, deploy CrowdStrike on IT endpoints, and monitor OT traffic patterns through our SOC for anomalous behaviour.
Legacy systems resist modernisation
Phased cloud migration with zero production disruption
We modernise non-critical workloads first — email, ERP peripherals, analytics — while wrapping legacy OT systems in secure, monitored envelopes. Cloud and on-prem coexist seamlessly.
Case Study
How a Chennai Auto-Parts Manufacturer Cut Downtime by 60%
A mid-market auto-parts manufacturer with 3 production facilities deployed SentosIQ predictive monitoring across their plant-floor IT infrastructure. Within 6 months, unplanned downtime dropped 60% and their IT team reclaimed 20 hours/week from reactive firefighting.
60%
Downtime reduction
20 hrs/wk
Reclaimed from firefighting
3
Facilities monitored
Relevant Services
Services tailored for manufacturing
FAQs
Manufacturing-specific questions
Modernise Your Factory Floor IT
Book a free manufacturing IT assessment. We'll evaluate your OT/IT landscape, identify predictive maintenance opportunities, and map a modernisation roadmap.