Manufacturing has topped the cyberattack target list for four years straight, according to IBM’s 2025 threat report. Attackers use stolen credentials and system flaws to hit connected equipment and ICS gateways, making industrial IoT security essential for business survival, not just IT hygiene.
Every day, your plant relies on Industrial IoT (IIoT) systems: sensors, controllers, and machines that share data across the floor. These systems enable real-time monitoring, predictive maintenance, and automation that cut downtime and boost output.
Examples include vibration sensors, environmental monitors, programmable logic controllers (PLCs), human-machine interfaces (HMIs), RFID tracking, and SCADA devices. Together, they form the backbone of Industry 4.0..
Key takeaways
- Map every IIoT and OT asset to uncover blind spots before attackers exploit them.
- Segment IT and OT networks so a phishing email in accounting never shuts down production.
- Enforce role-based access and MFA to cut off credential theft at its root.
- Monitor device behavior in real time to detect anomalies that attackers use to move laterally.
- Build and test an OT-specific incident response plan to recover operations without prolonged downtime.
The security risks unique to IIoT in manufacturing
You face security challenges that traditional IT defenses cannot solve. Industrial IoT security demands a different mindset, because vulnerabilities in operational technology (OT) affect both productivity and safety.
1. OT legacy systems exposed to the internet
Remote access gaps, such as VPN flaws or open RDP ports, don’t just expose IT systems. They give attackers a direct path to halt production and disrupt infrastructure.
2. Lack of built-in security in IIoT devices
Many IoT devices in manufacturing use default passwords, weak authentication, or lack a straightforward update process. Missed patches leave long-term vulnerabilities and expand your attack surface.
3. Complex mesh of vendors, protocols, and gateways
You rely on devices from many vendors, each with unique communication protocols. A single misconfigured application programming interface (API) can compromise the entire environment.
This patchwork ecosystem increases risks and complicates protection.
4. Flat networks that mix IT and OT
Without proper network segmentation, IT and OT remain connected. A phishing attack in finance can spread into industrial control systems (ICS). Attackers use flat networks to disrupt production and steal data.
5. Limited visibility and monitoring
Traditional antivirus software cannot detect or protect against threats from IIoT sensors or controllers. This blind spot leaves nearly half of manufacturers exposed to attacks, risking uptime, safety, and compliance. If you don’t know what’s connected, you can’t protect it.
Why ignoring IIoT security costs millions in downtime and fines
IIoT security gaps directly threaten revenue, safety, and competitive position.
- Downtime: Unplanned outages can cost over half a million dollars per hour and halt your supply chain. Even brief outages can cost major manufacturers over half a million dollars per hour, compounding into staggering annual losses.
- Compliance failures: Regulations such as NIST 800-171 and International Traffic in Arms Regulations (ITAR) carry heavy penalties if ignored.
- Intellectual property theft: Espionage targeting design data or proprietary processes undermines your competitive edge.
- Reputation damage: Clients lose trust when security breaches disrupt critical infrastructure.
Verizon’s 2025 Data Breach Investigations Report (DBIR) shows espionage motives rising to 20%, 1,607 confirmed breaches, and malware actions in 66% of incidents, up sharply from prior years. The data confirms: expanding IIoT without protection invites downtime, theft, and lasting damage.
6 practical steps manufacturers can take to protect uptime
Securing IIoT is practical, step-by-step work. Each action builds resilience into your operations, protecting both productivity and safety.
- Map every asset
You can’t defend what can’t be seen. Start with a complete inventory of IIoT devices, controllers, and OT endpoints. This reduces blind spots and improves protection across your environment.
- Segment IT and OT networks
Use virtual local area networks (VLANs), firewalls, and demilitarized zones (DMZs) to stop attackers from moving between IT and OT. Following NIST SP 800-82 zoning guidance ensures that a ransomware incident in accounting never reaches your production line.
- Enforce role-based access
Remove shared logins and tie permissions to roles. Require strong authentication and multi-factor authentication (MFA) on all critical systems. Adopting zero trust principles strengthens OT security while maintaining functionality.
- Monitor device behavior in real time
Static defenses are not enough. Deploy tools that learn normal device behavior, then flag anomalies instantly. Real-time monitoring helps you detect early signs of intrusion or denial of service attempts before they escalate.
- Update firmware and patch systems
Unpatched systems are prime targets. Create a patching cycle, even a manual one, across IIoT and OT. Standards like IEC 62443 recommend risk-based patching that protects automation without disrupting production.
- Build an OT incident response plan
Most incident response (IR) plans typically stop at the IT department. You need one for your plant floor. CISA’s checklist calls for urgent but straightforward steps:
- Remove internet exposure
- Change credentials
- Segment networks
- Enforce MFA
- Monitor and log events
- Aligning IT/OT response gives you a realistic playbook to contain cyber threats and recover quickly.
How Keystone keeps your plant running securely
You need a provider who knows how industrial systems differ from office IT. Keystone delivers focused OT security services that address the realities of plant operations.
- Complete visibility into every connected device, so no blind spot goes unprotected.
- Production-safe segmentation that reduces exposure without slowing operations.
- Intelligent monitoring that learns device behavior and spots anomalies before they escalate.
- Secure remote access for vendors and staff without increasing risk.
- Compliance alignment with NIST, ITAR, and IEC 62443 to avoid costly fines.
- Resilient recovery plans that get production back online fast after an incident.
With Keystone, you’re not just choosing a service provider; you’re gaining a partner dedicated to keeping your plant running.
Our approach reduces risk, safeguards uptime, and gives you confidence to modernize without trading speed for safety.
Are your IIoT devices creating hidden risk?
Most plants overlook basic safeguards, leaving blind spots in their industrial IoT security strategy. Use this quick self-check to evaluate your risk posture:
- No updated inventory of IIoT or OT devices
- IT and OT networks remain unsegmented
- No monitoring of OT network traffic
- Sensors and controllers were never patched
- The incident response plan only covers IT, not OT
If two or more apply, attackers can exploit gaps in your environment. A risk assessment from experienced providers highlights weak points and gives you a roadmap to stronger protection.
Industrial IoT security is no longer optional. Attacks against manufacturers are rising, and every unprotected system expands your risk. By securing IIoT environments, you reduce downtime, safeguard intellectual property, and strengthen resilience across critical operations.
With attacks rising, every unprotected device adds risk. Securing IIoT today means fewer costly outages, stronger IP protection, and greater resilience across operations.
Now is the time to close security gaps, align IT and OT defenses, and safeguard the future of your plant.
Book your free IIoT security assessment today with Keystone to discover your top 3 risks and how to fix them without downtime.
FAQs
What makes industrial IoT security critical for manufacturers?
You must secure IIoT systems because attacks now target operational technology (OT) directly, not just IT networks. Unprotected sensors, PLCs, and gateways expose production to downtime, safety risks, and regulatory penalties.
How does network segmentation strengthen industrial IoT security solutions?
Segmentation blocks lateral movement between IT and OT, preventing breaches in one area from reaching production systems. NIST SP 800-82 provides clear guidance on zoning, access control, and monitoring that reduces exposure and protects production uptime.
What are the top security risks for industrial IoT devices today?
The most urgent risks are unpatched firmware, weak credentials, and poor visibility into device activity. Hackers use these gaps to launch ransomware or disrupt operations.
