If you’re responsible for keeping industrial processes running smoothly, the threats to your Industrial Control Systems (ICS) aren’t just technical; they also pose operational, financial, and reputational risks. ICS environments power modern manufacturing, from PLCs on the plant floor to supervisory systems that run entire facilities.
But today, they’re being actively targeted. As more manufacturers connect operational technology (OT) networks to IT systems, the risk of cyberattacks increases. Outdated protocols and unsecured devices aren’t the only issues. Cyberattacks can disrupt your systems, lead to safety failures, and result in costly downtime.
The 2024 SANS ICS/OT Cybersecurity Survey found that OT-specific monitoring adoption increased from 33% in 2019 to 52% in 2024. Still, only 34% of organizations train in ICS cyber-ranges, and over 50% secure OT environments without relevant certification. It shows progress in tools, but there are serious gaps in fundamentals, such as training, risk management, and incident response planning.
Ransomware attacks on industrial infrastructure increased by 87% in 2024, with the manufacturing sector suffering the most significant impact. It’s clear: industrial control system security isn’t optional. To maintain uptime, safety, and compliance, you need proven security solutions specifically designed for ICS networks, not repurposed IT tools.
In this guide, you’ll learn how to strengthen your ICS cybersecurity posture, reduce cyber incidents, and build a proactive strategy to protect your operations.
Key takeaways
- If your OT and IT systems aren’t segmented, your entire operation is exposed. Establish robust boundaries with firewalls and DMZs to prevent threats from escalating through your critical systems and infrastructure.
- Relying on legacy ICS without modern cybersecurity drills is like running a plant with no fire exits. Invest in threat simulations and real-time response training, not just new tools.
- Certifications are helpful, but deep expertise in securing industrial systems is essential. Choose partners who understand supervisory control, PLC logic, and uptime-critical environments, not just those who meet the minimum requirements.
- Secure remote access before ransomware exposes the gaps. Audit vendor logins, revoke default credentials, and require MFA across every access point today.
- ICS risks aren’t just technical; they also pose a threat to your production and reputation. Make cybersecurity a core part of your operational strategy, not just a line item on the IT checklist.
Why are ICS systems vulnerable?
Unlike modern IT systems, which are built with cybersecurity in mind, most ICSs were designed for isolation and longevity, rather than connectivity and constant patching. This makes them uniquely susceptible to today’s evolving cyber threats.
Legacy systems, modern threats
Many ICS components are decades old and utilize proprietary protocols with limited security. These legacy systems were never designed to withstand modern attackers, including state-sponsored adversaries or ransomware gangs.
Expanded attack surface through connectivity
The increased reliance on Internet of Things (IoT) sensors, cloud-based analytics, and remote monitoring has expanded the ICS network. Every new connection opens a door for attackers. In 2024, over 145,000 ICS devices were exposed to the internet globally, with more than a third located in the U.S. alone (Censys).
IT-OT convergence without proper segmentation
In many facilities, there is little to no segmentation between operational technology (OT) networks and traditional IT systems. A breach in one area can quickly spread to another, compromising both digital assets and physical processes.
Supply chain and third-party risks
ICS environments often rely on multiple vendors and service providers. Each of these access points introduces risk. Unsecured remote access, shared credentials, and unmonitored third-party tools can provide unauthorized entry.
Common threats targeting ICS
Threats include:
- Ransomware: Disrupting critical operations
- Malware: Infiltrating or damaging control logic
- Unauthorized access: Gaining control over systems
- Supply chain attacks: Using vendors as attack vectors
Table: Traditional OT security vs. Modern ICS cybersecurity
| Aspect | Traditional OT Security | Modern ICS Cybersecurity |
|---|---|---|
| Network Design | Flat networks, minimal segmentation | Segmented networks, layered defenses |
| Access Control | Basic password authentication | Role-based access + MFA |
| Monitoring | Manual logs, periodic reviews | Real-time monitoring + anomaly detection |
| Updates & Patching | Rare, done during long outages | Scheduled, risk-prioritized maintenance windows |
| Vendor Access | Unrestricted or shared credentials | Secure VPNs, session tracking, and access expiry |
| Response Plans | Generic or IT-centric | ICS-specific playbooks and workflows |
| Training & Awareness | Minimal, focused on operations | Regular training, tailored to the ICS threat landscape |
What happens if you ignore ICS cybersecurity?
If you’re wondering whether your ICS environment is truly secure, ask yourself this: What would it cost if your critical systems were to go down today? Imagine a ransomware attack locking out your control systems mid-shift. Production halts. Your team can’t access supervisory control systems. Contracts get delayed. Safety features fail. You’re facing millions in losses before the end of day two.
This kind of attack has already happened to many manufacturers. In 2024, the Federal Bureau of Investigation (FBI) reported over 4,800 cybersecurity complaints from critical infrastructure organizations, with ransomware being the leading cause.
The actual cost of ignoring ICS vulnerabilities includes:
- Operational downtime
- Emergency repairs and reactive labor
- Lost contracts and inventory
- Regulatory fines
- Reputational damage that can ripple for years
When you strengthen your cybersecurity strategy by investing in network segmentation and implementing modern threat detection tools, you’re not just protecting data; you’re protecting your people, processes, and production.
What to look for in an ICS cybersecurity partner
Don’t settle for a general IT provider; look for a cybersecurity partner who knows OT inside and out. Including:
Expertise across OT and IT systems
Your partner should understand PLCs, supervisory control and data acquisition (SCADA) systems, and distributed control systems (DCS)
Ability to integrate security without halting production
Cybersecurity shouldn’t disrupt operations. The right provider can secure systems with minimal downtime.
Local and responsive support
Choose a provider who can respond quickly, understands your physical environment, and doesn’t treat your facility like just another data center.
Proven results in manufacturing environments
Look for testimonials, uptime metrics, and real-world ICS cybersecurity case studies, not generic IT anecdotes.
Why manufacturers choose Keystone Technology Consultants
You’ve seen what’s at stake. From supervisory control failures to cyberattacks on critical systems, manufacturers like you need more than basic IT support. You need a cybersecurity strategy designed specifically for industrial environments; one that strengthens threat detection, secures OT networks, and protects automation from the inside out.
For over 25 years, Keystone Technology Consultants has helped manufacturers implement industrial cybersecurity solutions that fit their workflows, rather than hindering them. We understand how to apply advanced security measures to protect programmable logic controllers, enable intelligent network segmentation, and defend integrated control and safety systems (ICSS) environments without halting production.
Here’s why clients trust us:
- Deep knowledge of industrial control systems, from SCADA to PLCs
- Real-world success securing automation across complex industrial processes
- Fast, local support that understands the urgency of OT disruptions
We’re here to help you take control of your security posture, reduce cyber risk, and gain the threat intelligence you need to keep your plant safe.
Book your ICS risk assessment with Keystone today.
FAQs
What is Industrial Control System (ICS) cybersecurity?
Industrial Control System (ICS) cybersecurity refers to the protection of systems, such as Supervisory Control and Data Acquisition (SCADA), Programmable Logic Controllers (PLCs), and Distributed Control Systems (DCS), from cyber threats. It helps safeguard both the digital infrastructure and the physical operations that power industrial environments.
How is Operational Technology (OT) security different from Information Technology (IT) security?
Information Technology (IT) security focuses on protecting data and securing enterprise networks. Operational Technology (OT) security, on the other hand, protects physical systems, such as machines and control equipment. OT systems require specialized strategies because they often run continuously, utilize legacy hardware, and prioritize safety and uptime over data management.
Can my IT team manage ICS security?
Not entirely. While your Information Technology (IT) team understands networks and cybersecurity, Industrial Control System (ICS) environments have unique risks. These include legacy systems, real-time control, and limited downtime windows. A combined approach is ideal, but ICS security should involve experts familiar with industrial processes and technologies.
