In an era of digital transformation, automation is no longer a luxury — it’s a necessity. Industrial environments, once resistant to rapid technological change, are now embracing automation to streamline operations, reduce errors and enhance productivity. At the heart of this shift lies DevOps: A methodology that fosters collaboration, accelerates deployment and enables continuous improvement.
DevOps methodologies are driving boundless automation in traditionally complex operational technology (OT) settings. From manufacturing to utilities and logistics, DevOps professionals are uniquely positioned to bridge the gap between software and machines, transforming industrial workflows through smarter, more integrated systems.
The Role of DevOps in Industrial Automation
DevOps is built on principles of collaboration, automation, iterative improvement and shared responsibility. While these ideas originated in software development, their impact is now reshaping industrial environments as well.
In complex OT settings where machines, sensors and control systems operate 24/7, manual workflows and siloed teams can lead to inefficiencies and costly downtime. DevOps helps eliminate these roadblocks by applying the same automation-first mindset that revolutionized software delivery. Here’s how DevOps is transforming industrial automation:
- Continuous Integration and Deployment (CI/CD): Automated pipelines allow for rapid testing and deployment of industrial control software, firmware updates and configuration changes without disrupting production.
- Infrastructure as Code (IaC): OT networks, PLC configurations and device settings can now be defined and managed programmatically, ensuring consistency across facilities and eliminating human error.
- Monitoring and Observability: DevOps enables real-time monitoring of both digital systems and physical assets, allowing operations teams to spot trends, detect anomalies and act proactively.
- Feedback Loops: DevOps encourages short feedback cycles — essential for refining industrial automation strategies and minimizing operational waste.
Bulletproofing the Plant Floor With Automation
By integrating DevOps tools and culture into industrial settings, organizations unlock powerful automation benefits that drive productivity and reliability. Consider the following examples of key areas where automation excels:
- Machine Configuration & Provisioning
Automate the setup and calibration of control systems, reducing deployment time and ensuring standardized environments across multiple sites.
- Data Collection and Analysis
Collect data from industrial sensors and edge devices, such as handheld gas flow meters and feed it into centralized platforms for predictive maintenance, compliance reporting and optimization.
- Incident Response and Recovery
Automatically detect and respond to system anomalies, minimizing downtime and preventing small issues from escalating into production halts.
- Safety and Compliance Audits
Automate routine safety checks, environmental measurements and audit reporting for seamless regulatory compliance.
Case in Point: Empowering Maintenance Teams
Maintenance in industrial environments has historically been reactive. However, when DevOps is combined with smart asset management tools, it evolves into a proactive, data-driven discipline.
For example, teams can use IoT-connected devices like a handheld gas flow meter to gather real-time readings. If the flow levels are abnormal, the system automatically creates a ticket in the maintenance platform. It then cross-references the issue with historical data to determine the likely cause. Based on that analysis, a repair recommendation is generated and scheduled without human intervention. This kind of intelligent automation reduces downtime, improves safety, ensures compliance and extends the life of equipment.
Culture and Collaboration Are Key
Implementing DevOps in industrial settings isn’t just about tools — it’s about fostering a culture that supports transformation. Automation thrives when cross-functional teams work toward shared goals and openly exchange knowledge.
When DevOps professionals collaborate with OT teams, they help build a culture of shared accountability for uptime and performance. Together, they can plan automation initiatives in sprints, hold regular retrospectives to refine processes and continuously improve operations. These cultural shifts can be challenging, but they’re also where the most impactful change happens. Once IT and OT teams begin speaking the same language, innovation accelerates — and so does progress.
Overcoming Industrial Challenges With DevOps Thinking
Applying DevOps to industrial automation is not without its challenges:
- Legacy Systems: Many facilities still run outdated equipment that isn’t easily integrated with modern tools.
- Cybersecurity Concerns: Expanding networked automation increases the attack surface, requiring built-in security practices from the start.
- Skill Gaps: Traditional OT staff may be unfamiliar with DevOps concepts, requiring training and change management.
However, these challenges can be addressed through:
- Containerization and API gateways to wrap legacy systems
- DevSecOps practices that build security into every phase of deployment
- Cross-training programs to upskill operations staff on automation tools
The Future Is Automated and DevOps Is the Key
The industrial world is at a turning point. As demand for efficiency, flexibility and data-driven decision-making rises, automation becomes the path forward. And DevOps is the engine that powers that journey.
By applying DevOps principles — automation, collaboration, continuous delivery and real-time monitoring — practitioners can modernize industrial systems, eliminate silos and unlock powerful gains in uptime, quality and throughput.
For DevOps professionals, the opportunity is clear: Bring your expertise to the plant floor. Whether it’s integrating a handheld gas flow meter into a predictive maintenance workflow or building CI/CD pipelines for PLC software, your skills can help shape the next generation of industrial innovation.
