Manufacturers strengthen OT security as threats intensify

Industrial organisations are placing greater emphasis on securing operational technology (OT) environments as cyber threats become increasingly sophisticated, prompting manufacturers to rethink how they protect critical infrastructure without disrupting production.

Unlike traditional IT environments, which prioritise protecting business systems and sensitive data, OT networks control the machinery and industrial processes that underpin sectors such as manufacturing, mining, energy, food production and pharmaceuticals. 

As these environments become more connected in the digital age and through remote access technology, however, they are also becoming more attractive targets for cybercriminals.

This shift is driving growing recognition that OT cybersecurity requires its own dedicated strategy, not just extending conventional IT security practices into factory environments, according to VP and Head of Regions for Life Cycle Services at Rockwell Automation, Inba Rathinam.

"OT and IT cyber networks are very, very different, in their purpose," Rathinam said.

"OT networks are designed to manage industrial systems and processes, whereas IT networks are designed to manage business systems and processes."

The distinction is becoming increasingly important as companies modernise their operations, while continuing to rely on older equipment that may have been installed 10 or 20 years ago.

Unlike corporate IT infrastructure, which is routinely upgraded and patched, industrial control systems often remain in service for decades because replacing them can require costly plant shutdowns. 

This longevity helps maximise the return on investment from industrial assets, but it also creates unique cybersecurity challenges.

Many manufacturers only perform major upgrades during scheduled maintenance periods, leaving older equipment operating alongside modern connected technologies. The result is a complex environment where security must be balanced with operational continuity.

Instead of regularly replacing hardware, organisations are increasingly focused on strengthening network architecture through segmentation, visibility and continuous monitoring.

Separating IT and OT environments with robust firewalls remains one of the most important security measures, as well as proactively monitoring industrial control systems for emerging threats, instead of relying solely on traditional perimeter defences.

While some organisations continue to use techniques such as air-gapping to isolate operational networks from the internet, increasing levels of connectivity mean these protections alone are no longer enough.

"Today's systems are connected," Rathinam said. 

"Whatever air-gapping you do, there is always a risk of threats coming into the system. That's where you need to be really proactive."

The consequences of a successful cyberattack on an OT environment can extend far beyond data loss.

Where attacks on business systems typically focus on stealing information or disrupting office operations, attacks targeting operational technology have the potential to halt production lines, damage expensive equipment, interrupt essential services and, in more extreme cases, endanger human safety.

"These (systems) are managing critical infrastructure," Rathinam explained. 

"The impact can be the safety of human lives, or it can be valuable assets getting destroyed."

Growing awareness of these risks is prompting more companies to assess the security of their industrial networks.

A key challenge is that many businesses lack a complete inventory of the equipment operating within their facilities. Devices installed years or even decades ago may still be connected to operational networks, despite receiving little attention from operators.

As a result, cybersecurity projects usually begin with asset discovery and network assessments to identify legacy equipment, understand potential vulnerabilities and prioritise remediation efforts.

Consulting-led assessments typically include evaluating existing network architecture, identifying gaps in security controls and developing remediation plans before implementing ongoing monitoring and threat detection capabilities.

Artificial intelligence is also beginning to reshape industrial cybersecurity, although its influence is still in its early stages.

As AI tools become more widely adopted, organisations are exploring how they can improve engineering processes, automate routine tasks and strengthen cybersecurity operations. 

But on the other side, cybercriminals are expected to leverage the same technologies to develop more sophisticated attacks, creating an arms race between defenders and bad actors.

"As much as the technology changes, the threat factor is also changing fast," Rathinam said. "The threat actors are also working in parallel."

Security has become one of the highest priorities for companies as awareness of operational risks continues to grow.

While threats to industrial systems have existed for many years, Rockwell customers now have a far better understanding of the operational and financial consequences of successful attacks.

That increased awareness is resulting in stronger investment in cybersecurity strategies designed specifically for OT, reflecting a broader industry shift towards protecting the systems that underpin critical infrastructure.