If you manage a manufacturing operation, ransomware is now your most serious operational threat. Between 2018 and 2024, manufacturing companies experienced 858 confirmed ransomware attacks, resulting in an average daily loss of $1.9 million due to downtime and a total loss of more than $17 billion.
Attackers now aim to halt production faster than they can steal data. While information technology (IT) protects your data and communications, operational technology (OT) controls the industrial processes, sensors, and programmable systems that keep your operations running smoothly. When these networks intersect, vulnerabilities in industrial cybersecurity and ICS security can expose both production and business systems.
This article compares OT security and IT security in manufacturing, highlighting where risks diverge, why integration is crucial, and the steps that help maintain production safety without compromising uptime, compliance, or performance.
Key takeaways
- Prioritize uptime and safety in OT; protect data and privacy in IT. You need clear distinctions between operational technology and information technology to build the proper defenses.
- Address legacy systems and vendor access risks early. Older industrial systems and remote connections continue to be the primary entry points for attackers.
- Build shared visibility across IT and OT networks. Enhanced industrial cybersecurity visibility and OT threat monitoring enable you to detect anomalies before they lead to downtime.
- Combine defenses to support both compliance and production goals. Integrated controls enable you to stay audit-ready while maintaining continuous operations.
- Partner with a managed security provider to strengthen resilience. Expert support ensures ongoing monitoring, rapid response, and reduced operational risk.
Understanding the difference between IT and OT systems
In manufacturing, Information Technology (IT) and Operational Technology (OT) function in connected yet fundamentally different factory networks, each facing unique security risks. IT systems manage business data, communications, and enterprise applications, including ERP and email.
Their main threats involve data exfiltration, credential theft, and service disruption, all of which compromise confidentiality. A cyberattack on IT may slow operations, but it rarely stops production entirely if core IT networks remain intact.
OT manages the production systems powering real-world output. They control machinery, sensors, and automation across OT environments, utilizing industrial control technologies such as Programmable Logic Controllers (PLCs) and Supervisory Control and Data Acquisition (SCADA) systems.
These rely on stable operating systems and consistent data acquisition to maintain precision and safety. Because OT functions in real time, even a minor disruption can halt output or create physical danger.
The two domains increasingly overlap through connectivity supported by the Industrial Internet of Things (IIoT). As IoT is transforming the manufacturing industry, this convergence delivers powerful data insights but also introduces new cybersecurity challenges. Data from the shop floor now feeds analytics, maintenance, and planning tools. Logging into email versus adjusting a conveyor’s speed: one risks data, the other risks safety. That distinction matters most when assessing cybersecurity priorities.
According to NIST SP 800-82r3, OT refers to programmable systems designed for predictable operation and high availability.
OT security vs IT security: key differences
When comparing IT security and OT cybersecurity, the key difference lies in what each protects. IT networks secure data and maintain business continuity. OT systems protect uptime, equipment, and worker safety.
A data breach in IT might expose customer information, while an OT incident can halt production or cause physical damage. For example, a cyberattack on a manufacturing line can stop production for hours and result in millions of dollars in downtime.
Priority focus: IT protects data; OT protects uptime and safety
IT security focuses on protecting information assets, ensuring confidentiality, integrity, and access control. In contrast, OT cybersecurity aims to ensure that industrial operations run safely and securely. A successful cyberattack on OT infrastructure can disrupt production or create safety hazards, making uptime and reliability the top priority.
System lifecycles: OT systems often last decades, unlike short IT refresh cycles
IT hardware and software are replaced regularly, often every three to five years. OT systems, by contrast, are designed for long-term use, sometimes 20 years or more. Because these systems control physical processes, upgrades can be complex and risky, requiring extensive testing to avoid operational disruptions.
Patch management: OT patches can’t always be applied immediately; downtime is too costly
In IT, patches and updates are routine maintenance tasks. OT environments cannot patch as easily, since installing an update on a live production line can cause downtime worth thousands of dollars per hour. As a result, OT teams validate each update before deployment to maintain stability while minimizing vulnerabilities.
Protocol complexity: OT uses specialized communication protocols that lack encryption
Many OT networks still rely on legacy industrial protocols such as Modbus, DNP3, and Profibus. Manufacturers designed these systems for reliability, not security. Most lack built-in encryption or authentication, allowing attackers to intercept or alter commands when networks are poorly segmented or monitored.
Threat impact: IT attacks steal data; OT attacks can stop production or endanger workers
The consequences of a cyberattack differ significantly. In IT, the typical goal is to steal data or gain financial benefits. In OT, the impact can extend to safety systems, production downtime, or even environmental damage. In OT, cybersecurity protects people and processes as much as data, making it essential to align IT security and OT cybersecurity strategies for full operational resilience.
The risks of ignoring OT security in manufacturing
Ignoring OT security exposes you to some of the most damaging cyberattacks in modern industrial environments. As production systems become more connected, ransomware and supply chain breaches are increasing in both frequency and sophistication. These threats not only steal data but can also halt equipment, interrupt logistics, and cause severe downtime that affects the entire supply chain.
Attack frequency continues to rise across critical manufacturing sectors. Ransomware campaigns that once targeted corporate IT systems now directly disrupt factory floors and control systems. Conducting a manufacturing risk assessment helps identify potential weaknesses before attackers can exploit them.
In August 2025 alone, third-party cloud breaches tied to Salesforce and other vendor platforms compromised more than 15 million customer records across organizations such as Allianz, TransUnion, and Farmers Insurance.
Vendor access introduces another hidden risk. Many plants rely on external partners for remote maintenance, but unmanaged remote access often becomes an invisible pathway for attack. A supplier’s compromised VPN, for example, can enable lateral movement from IT to OT devices, providing attackers with direct access to production assets.
Legacy exposure amplifies these risks. Many older controllers still run with default credentials or no authentication, leaving them vulnerable to exploitation. Bitsight reported that global ICS and OT exposure grew by 12% in 2024, with roughly 180,000 systems still accessible from the public internet.
But technical exposure is only half the story. The other half lies in the operational challenge: 65% of industrial security professionals said their biggest hurdle was integrating aging OT systems with modern IT infrastructure. Without modern, proactive security controls, manufacturers face stalled production, damaged equipment, and lasting reputational harm. Embracing IT modernization in manufacturing enables the replacement of legacy systems with scalable, secure solutions.
Together, these trends underscore the urgent need for unified IT and OT defenses.
Integrate IT and OT cybersecurity strategies effectively
As the line between IT and OT continues to blur, manufacturers must adopt a unified strategy to reduce risk and strengthen resilience. Effective IT/OT convergence aligns compliance, uptime, and performance goals. It safeguards both digital and physical assets.
Start by segmenting networks using Purdue zoning and firewalls that separate corporate systems from control networks. Proper segmentation limits the impact of a compromise and prevents unauthorized communication between layers.
Next, apply Zero Trust principles across the environment. Limit vendor and operator permissions, verify every connection request, and authenticate devices before granting access. This approach is increasingly vital as IIoT and IoT grow across production environments.
Continuous monitoring is another cornerstone of integrated IT and OT cybersecurity. Baseline OT protocols, detect unsafe commands, and track east-to-west network traffic to identify anomalies. Organizations that baseline OT protocol activity detect threats earlier and respond faster.
Finally, build collaboration between IT and OT teams. Cross-train staff, share threat intelligence, and unify incident response playbooks to ensure consistent action when a threat occurs.
For example, creating a mirrored data flow between MES and ERP systems provides real-time visibility without causing downtime. Leveraging co-managed IT for manufacturing enhances these integrations while maintaining production security and compliance. This supports compliance with NIST and similar cybersecurity frameworks while maintaining stable operations.
Example: How OT Neglect Stopped Production
This example, drawn from a composite of real manufacturing incidents, shows how a single missed update can trigger cascading failures. A food packaging plant was hit by ransomware after postponing a critical firmware update on one of its Programmable Logic Controllers (PLCs).
The attack entered through an outdated vendor connection and quickly spread across connected OT systems, shutting down conveyor lines and robotic palletizers. Within hours, the Supervisory Control and Data Acquisition (SCADA) interface froze, halting all industrial processes and leaving operators blind to equipment status.
The attack halted production for 48 hours, causing spoilage and delays throughout the supply chain. Applying risk management in the supply chain principles helps prevent cascading disruptions after a cyber event. The total downtime cost far exceeded what preventive maintenance and security monitoring would have required; an outcome that proactive IT support could have helped prevent.
Recovery demanded tighter network segmentation, stronger vendor credential policies, and continuous monitoring of physical systems to detect unsafe commands before they reached machinery. After restoring control, the manufacturer deployed updated incident response playbooks and automated firmware management for all PLCs and robots.
This case highlights the importance of integrated IT and OT protection. Prevention costs far less than an unplanned outage, both in financial and reputational terms.
How Keystone helps manufacturers bridge IT and OT security
At Keystone, our team helps you protect both IT and OT environments through unified, compliance-ready security programs. We understand that production and data systems are deeply interconnected, so we focus on defending both layers equally to maintain stability and trust.
Dual expertise enables our specialists to manage both business networks and industrial controls simultaneously, allowing them to oversee both areas. We secure routers, servers, and endpoints while protecting PLCs, sensors, and automation controllers that keep production moving.
Through continuous monitoring, we track ERP, MES, and SCADA systems for any suspicious activity. Our analysts baseline regular activity, detect deviations, and use advanced security tools to contain risks before they cause downtime or data loss.
Compliance alignment is another cornerstone of our approach. We align client defenses with major cybersecurity frameworks, including NIST, ISO 27001, and CMMC. This ensures that security practices meet audit requirements while supporting productivity goals.
We also emphasize rapid response to limit the impact of any breach. Our playbooks outline clear containment, recovery, and communication procedures that maintain uptime and operational integrity. For example, our team recently identified abnormal OT traffic in a hybrid network and contained it before it caused disruption.
By combining layered defense, network segmentation, and proactive protection of critical OT assets, Keystone delivers scalable OT security solutions that enhance resilience across modern manufacturing systems.
Unified security for modern manufacturing
Protecting your business today means securing both information and operations together. Co-managed IT accelerates Industry 4.0 in manufacturing by aligning advanced cybersecurity, automation, and continuous improvement. True resilience depends on a unified approach that balances network security, uptime, and safety across every system.
When IT and OT remain siloed, even small vulnerabilities can multiply, slowing production and undermining operational efficiency. But when they work in harmony, data flows securely, machines stay online, and compliance becomes easier to maintain.
Manufacturers that integrate defenses can detect threats more quickly, recover more efficiently, and make smarter, data-informed decisions. The goal is not only to prevent attacks but also to establish a secure foundation for growth and innovation.
Now is the time to take the next step. Schedule a manufacturing cybersecurity assessment with Keystone today to evaluate your IT/OT security readiness.
Together, we can strengthen your defenses, protect productivity, and ensure your operations are ready for whatever comes next. Discover how to build cyber resilience in manufacturing to prepare for future threats and facilitate faster recovery.
FAQs
How can manufacturers protect industrial control systems from hackers and malware?
Keep industrial control systems (ICS) separate from business networks and use multi-factor authentication for every login. Patch software on schedule, control vendor access, and watch for strange network commands. Follow OT cybersecurity standards, such as NIST SP 800-82 or IEC 62443, to maintain strong protection against hackers and malware.
What does effective IT/OT convergence look like in manufacturing cybersecurity?
In a secure factory, IT protects data while OT keeps machines running safely. Both teams share tools and follow the same access rules. This joint approach, known as IT and OT cybersecurity convergence, enhances visibility and mitigates cross-network risk. For example, shared dashboards enable both teams to spot threats more quickly.
How can IT cybersecurity teams prevent malware from spreading across factory networks?
Use network segmentation to separate business and control systems. Secure all endpoints and limit access to devices. Train staff to recognize phishing attempts and refrain from using USB drives on control hardware. Continuous monitoring and rapid isolation of infected machines are crucial to preventing malware in OT environments.
