Manufacturing’s OT Security Challenges: Rising Threats, Legacy Risks And The Path To Resilience

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By
The Protiviti View

Securing OT Systems Against Evolving Threats and Legacy Risks

Manufacturers face an unprecedented wave of cyber threats targeting their operational technology (OT) environments. Legacy systems, aging infrastructure and the rapid convergence of IT and OT have created a complex landscape where vulnerabilities are multiplying. Attackers, including cybercriminals and nation-state actors, increasingly view manufacturing as a prime target, not for data theft, but to disrupt operations and extort ransom. The stakes are high; downtime can cost millions per hour and supply chain dependencies mean risks extend beyond the factory floor. What makes this information vital now is the accelerating pace of digital transformation and connectivity in manufacturing, which expands the attack surface and demands immediate action to protect uptime, safety and reputation.

Success in securing OT environments hinges on collaboration, resilience and proactive measures. Key strategies include establishing strong governance, defining clear ownership of OT security and aligning with frameworks like NIST CSF or IEC 62443 segmenting networks to limit breaches and maintaining visibility over all assets, especially legacy devices. Continuous monitoring, robust incident response planning and role-based training for all staff to further strengthen defenses. Practical advice centers on reducing internet exposure, hardening access controls and managing third-party risks through strict policies and automated processes. Ultimately, building a culture of cross-functional teamwork and layered security helps manufacturers stay ahead of evolving threats, ensuring that production lines remain safe and reliable.

Important Insights:

  • Manufacturing OT environments are high-value targets for cyberattacks, especially ransomware.
  • Legacy systems and IT/OT convergence require urgent, coordinated security strategies.
  • Layered defenses, governance and continuous monitoring are essential for resilience.
  • Cross-functional collaboration and robust incident response plans are critical to operational security.