More than half of organizations experienced a material cyber incident in the past year, and leaders reported that attacks increasingly cause operational disruption rather than data loss, according to the World Economic Forum’s 2024 Global Cybersecurity Outlook, which draws on responses from executives across critical sectors worldwide.
As manufacturing operations connect OT systems to business networks, the business impact of cyber risk shifts from IT recovery to halted production.
Operational technology (OT) environments were once isolated and considered safe by design. That assumption no longer holds. OT systems are now interconnected with information technology, vendors, and cloud services, which exposes them to modern cyber threats.
Even as manufacturers strengthen IT cybersecurity, OT security in manufacturing remains lagging. Legacy equipment, limited visibility, and operational constraints make OT harder to secure. The result is a growing risk profile that directly impacts uptime, safety, and the supply chain.
Key takeaways
- Treat OT environments as high-risk systems that require dedicated security controls, not extensions of corporate IT.
- Address legacy equipment exposure before adding connectivity to prevent attackers from exploiting unmanaged access paths.
- Protect uptime and worker safety by prioritizing OT security investments alongside production reliability goals.
- Deploy purpose-built OT security tools designed for industrial protocols, real-time operations, and zero downtime tolerance.
- Leverage Keystone’s manufacturing expertise to align IT and OT security without disrupting production or compliance.
What makes OT security different from IT security?
OT systems prioritize uptime and safety, not cybersecurity
OT systems were designed to control physical processes continuously. PLCs, SCADA systems, and DCS platforms run production lines, utilities, and safety systems around the clock. Engineers built them to prioritize uptime, determinism, and safety.
Early OT designs rarely included cybersecurity controls. Authentication was minimal. Encryption was uncommon. Least-privilege access was not a requirement. In many environments, patching or rebooting systems still requires complete production shutdowns, making routine security maintenance difficult.
OT devices often run outdated or unsupported software
Many OT devices remain in service for decades. Human-machine interfaces may still run Windows XP or Windows 7. Controllers often rely on proprietary firmware that cannot be easily updated. Legacy protocols frequently lack encryption or authentication.
These constraints create persistent vulnerabilities. Unlike IT systems, OT assets cannot be replaced or patched during normal lifecycle activities without operational risk.
OT networks were not built for exposure
Most OT networks were initially flat and isolated. Shared credentials, broad access, and minimal segmentation remain common. Remote vendor access is often enabled with limited oversight or logging.
As OT networks connect to enterprise IT and external services, this architecture increases exposure. Once attackers gain a foothold, they can move quickly across OT environments.
A breach in OT impacts physical operations
When OT security fails, the impact is immediate and physical. Compromised controllers or HMIs can halt production, damage equipment, or bypass safety controls. These incidents trigger downtime, regulatory scrutiny, and safety risks, not just data loss.
Why OT risks keep growing (Even with better IT security)
1. Convergence of IT and OT environments
Industry 4.0 requires data to move between OT systems and enterprise platforms. That convergence expands the attack surface. Each new integration creates another path attackers can exploit.
36% of organizations now manage both IT and OT security under the same team.
In many incidents, attackers first compromise IT systems and then pivot into OT environments. A ransomware attack that starts on a corporate server can spread laterally and reach the plant floor.
2. Legacy machinery now connected to the internet
Machines never designed for networking now use IoT sensors, remote monitoring, and cloud dashboards. These connections often lack strong encryption, authentication, or access controls.
As a result, legacy OT assets gain external exposure without equivalent security protections.
3. Remote vendor access has become a major weak point
Manufacturers rely on OEMs and integrators for maintenance and troubleshooting. Remote access enables faster support, but it also creates risk.
Shared passwords, always-on VPN tunnels, and limited session logging remain common. One stolen vendor credential can provide direct access to production systems.
4. OT systems have limited or no security monitoring
Many OT environments lack endpoint detection, SIEM integration, or protocol-aware monitoring. Security teams often have blind spots across critical equipment.
28% of organizations lack an ICS/OT-specific incident response plan.
Without visibility, abnormal behavior goes undetected. You cannot secure what you cannot see.
5. Ransomware groups now specifically target OT
Ransomware groups increasingly target manufacturing because downtime is costly and hazardous. OT outages disrupt production and create pressure to pay quickly.
Ransomware attacks on organizations rose 66% in the second half of 2024.
OT attacks have increased 87 percent year over year, affecting both mid-sized and large plants.
6. Workforce and skill gaps in OT cybersecurity
Most IT teams lack deep experience with PLCs, SCADA, and industrial protocols. OT engineers understand production and safety, but often lack cybersecurity training.
This divide creates ownership gaps and inconsistent risk management across OT environments.
The real-world impact of weak OT security
Production downtime and missed orders
A single compromised HMI can stop an entire line. When you cannot trust controllers or supervisory control stations, teams often halt production to prevent unsafe behavior, which can lead to immediate downtime and customer and revenue impact. These cyber risks escalate quickly in industrial systems where even short outages disrupt tightly scheduled operations.
Equipment damage
Malicious commands sent to programmable logic controllers can overheat equipment, trigger safety shutdowns, or force machinery outside safe operating ranges. In industrial control systems, this type of damage often requires lengthy lead times for repairs, requalification, and inspection of critical infrastructure assets.
Safety incidents
OT cyberattacks can directly endanger workers by interfering with safety logic, alarms, or interlocks. In ICS environments, failures can trigger facility-wide environmental, health, and safety events that extend far beyond financial loss and expose organizations to long-term operational and legal risk.
Supply chain disruption
When a plant stops producing, suppliers and customers feel the impact immediately. OT-related cyber incidents ripple through the supply chain, mainly when manufacturers rely on just-in-time models or serve as sole suppliers within industrial ecosystems.
Regulatory and insurance consequences
Cyber insurers increasingly evaluate OT security posture separately from IT, especially for organizations tied to critical infrastructure. Weak security controls, limited threat detection, or undocumented incident response plans can result in higher premiums, denied claims, or regulatory penalties aligned with ISO and sector-specific requirements.
Why traditional IT security tools fail in OT environments
They cannot run agents on PLCs or industrial controllers
Most OT devices do not support endpoint agents, such as EDR or antivirus. Even when agents can be installed, they risk disrupting real-time control in industrial systems, making them unsuitable for many ICS environments.
IT tools do not understand industrial protocols
Standard IT security solutions do not interpret Modbus, Profinet, EtherNet/IP, or DNP3 traffic. Without protocol awareness, these tools miss malicious commands hidden in seemingly normal network traffic and fail to detect lateral movement within OT networks.
Scanning tools can cause outages
Active vulnerability scans can overwhelm fragile OT devices and crash legacy HMIs or controllers. In production environments, poorly timed scans often cause the very downtime security teams are trying to prevent.
IT patching strategies do not work in 24/7 production
IT patching assumes regular maintenance windows and system reboots. OT environments rarely allow this, forcing manufacturers to rely on compensating controls like firewalls, network segmentation, and zero-trust access rather than frequent patch cycles.
Why manufacturers need a managed OT security partner
OT security requires multidisciplinary expertise
Adequate OT security requires coordination between IT security engineers, OT engineers, network architects, and compliance stakeholders. Few manufacturers can maintain this level of expertise internally while keeping industrial operations running.
MSPs bring visibility tools manufacturers don’t have
OT-focused threat detection, asset discovery, and monitoring tools are expensive and complex to deploy. Managed security solutions provide visibility into OT network traffic and device behavior without disrupting production.
MSPs help implement controls without disrupting production
Experienced partners understand how to apply security controls safely in live environments. They design network segmentation, firewalls, and access policies that reduce the attack surface without interrupting operations.
MSPs operationalize frameworks (NIST, CIS, CMMC)
Security frameworks only reduce risk when applied consistently. Managed partners translate NIST, CIS, and CMMC guidance into actionable security strategies across IT and OT systems.
MSPs provide 24/7 monitoring across IT and OT
Cyber threats do not follow shift schedules. Continuous monitoring enables faster threat detection and response across both enterprise IT and OT environments.
Why manufacturers trust Keystone with OT security
Keystone understands the realities of production environments
Keystone works within the constraints of legacy equipment, limited downtime, and strict safety requirements. This experience ensures security improvements align with real operational priorities.
Expertise across IT, OT, and industrial cybersecurity
Keystone combines enterprise IT security knowledge with deep OT and ICS experience. This blend supports practical security solutions that protect industrial control systems without compromising reliability.
Keystone specializes in bridging OT and IT gaps
Keystone secures connectivity between IT and OT by limiting lateral movement, enforcing segmentation, and applying zero trust principles to remote access and data flows.
Manufacturing-specific incident response and risk assessment
Keystone delivers incident response and risk assessments tailored to industrial operations. Plans account for physical processes, safety impacts, and coordination between technical and operational teams.
A co-managed approach that supports internal teams
Keystone strengthens your team rather than replacing it. The co-managed model keeps internal stakeholders in control while extending coverage, visibility, and expertise across evolving cyber risks.
Final thoughts: OT security is now a business risk, not just a technical one
Availability threats ranked as the top cybersecurity risk in 2024.
OT risks continue to grow as manufacturing environments become more connected. Threat actors understand OT systems and actively target them. Manufacturers must secure operations without disrupting production.
The right OT security partner turns risk into resilience.
If you’re unsure how exposed your OT environment is, Keystone can help you assess your risk and prioritize the steps that protect production without slowing it down.
FAQs
What is OT security in manufacturing, and how is it different from IT security?
OT security in manufacturing protects systems that control physical production, not just data. It prioritizes uptime and safety, so controls must avoid disrupting operations.
How can manufacturers reduce OT security risks without causing downtime?
Manufacturers reduce OT security risks by using passive monitoring, network segmentation, and tightly controlled remote access. These measures limit exposure without stopping production.
When should manufacturers engage a managed IT partner for OT security?
Manufacturers should engage a managed IT partner when OT systems connect to IT networks or when vendors need remote access. A co-managed approach closes gaps without replacing internal teams.
