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From Reactive to Proactive: OT Security for Manufacturing

Summarize the Content of the Blog

Key Takeaways

OT security breaches cost manufacturers an average of $5.56 million, with downtime ranging from $50,000 to $2.3 million per hour

75% of manufacturing cyber incidents now target converged IT/OT systems, exploiting the gap between traditional IT security and operational requirements

Proactive security requires five strategic pillars: comprehensive visibility, network segmentation, threat intelligence, AI-powered detection, and framework-driven governance

Unified platforms like Splunk enable both security and operational intelligence, transforming fragmented data into actionable insights

Organizations achieving advanced security maturity (46%) report significantly fewer incidents and faster recovery times compared to reactive approaches

The factory floor has evolved from an isolated environment to a connected ecosystem—and cybercriminals have noticed.

For the fourth consecutive year, manufacturing holds an unwelcome distinction: it’s the #1 target for cyberattacks worldwide [1]. The statistics paint a stark picture—a 71% surge in threat actors specifically targeting manufacturing operations between 2024 and early 2025 [2], with ransomware attacks jumping 46% in just one quarter [3].

Yet here’s the troubling reality: while 80% of manufacturing companies report significant increases in security incidents, only 45% have adequately prepared their cyber defenses [4]. Even more concerning, approximately 95% of manufacturers have no dedicated OT security in place [5].

This gap persists because too many manufacturers still treat operational technology (OT) security as a reactive IT concern rather than recognizing it as a strategic business imperative that directly impacts production continuity, competitive advantage, and profitability.

The Hidden Cost of Reactive Security

Manufacturing downtime costs organizations an average of $255 million annually [7]. According to IBM’s 2024 research across the industrial sector breaches, average costs reached $5.56 million [9], with industry studies showing hourly downtime costs averaging $50,000 for typical operations and as high as $2.3 million per hour in automotive manufacturing, according to Siemens' 2024 analysis [8].

Why Manufacturers Are Prime Targets:

Cybercriminals understand manufacturing’s unique vulnerabilities. Production lines must run continuously, creating immense pressure to restore operations quickly when attacks occur—making manufacturers more likely to pay ransoms [5]. Legacy industrial control systems, often more than 20 years old, were never designed for internet connectivity, yet digital transformation initiatives increasingly connect these OT systems to IT networks, suppliers, and customers—expanding the attack surface exponentially [5]. Meanwhile, silos between IT and OT obscure visibility, creating blind spots that attackers exploit.

Why Traditional IT Security Fails in OT Environments

Research shows that 75% of manufacturing cyber incidents now target converged IT/OT systems [11], yet many organizations apply IT security playbooks to fundamentally different OT requirements.

IT environments prioritize data confidentiality and allow scheduled maintenance windows with regular patching. OT environments prioritize system availability and physical safety, requiring 24/7/365 uptime with equipment lifecycles spanning 15-25 years.

The convergence paradox: Industry 4.0 brings enormous benefits—predictive maintenance, real-time analytics, remote monitoring. But every connected sensor and cloud integration expands the attack surface, creating pathways for adversaries to move from corporate networks into production control systems.

According to Fortinet’s 2025 State of OT Cybersecurity Report, while 46% of organizations achieved advanced security maturity, this leaves more than half of manufacturers operating with inadequate protection [1].

The Proactive Security Framework: Five Strategic Pillars

1. Comprehensive Visibility: The Foundation

You cannot secure what you cannot see. Proactive security begins with complete visibility across all OT devices, systems, and network connections—including complete asset discovery, continuous network monitoring that baselines normal operations, vulnerability tracking prioritized by business criticality, and contextualized data that transforms raw signals into meaningful insights.

Modern manufacturers face data trapped in disconnected silos—manufacturing execution systems, quality databases, maintenance platforms, enterprise resource planning, and industrial control systems. By unifying operational and business data through platforms like Splunk, manufacturers gain visibility across production lines, assets, and facilities, enabling security teams to correlate events while empowering operations teams to investigate performance issues in real-time.

2. Network Segmentation: Defense in Depth

Network segmentation ranks among the most effective OT security controls [1], dramatically reducing attack surface and preventing lateral movement. Modern strategies incorporate microsegmentation with granular control at the device level, Zero Trust principles where every connection requires verification, dynamic policies that adapt based on behavior and threat intelligence, and strategic isolation using air gaps for critical systems.

3. Proactive Threat Intelligence and Hunting

Waiting for alerts means you’re already compromised. OT-specific threat intelligence [1] provides tactical insights about groups targeting your industrial sector, vulnerability intelligence affecting your equipment before widespread exploitation, indicators of compromise observed at similar organizations, and emerging patterns including custom malware designed for manufacturing [2].

Research reveals attackers are maintaining access within compromised environments for longer periods [2], making proactive hunting essential for early detection.

4. AI-Powered Detection and Investigation

Artificial intelligence transforms OT security from manual analysis to intelligent, automated defense [12]. AI delivers behavioral baselining where machine learning understands normal operational patterns, then flags deviations, predictive threat detection identifying emerging threats before incidents occur, automated response executing actions in seconds instead of hours, and reduced noise by distinguishing legitimate changes from malicious activity.

5. Framework-Driven Governance

52% of organizations now place OT security under their Chief Information Security Officer, up from just 16% in 2022 [1]. Leading organizations align IEC 62443 for technical implementation with NIST Cybersecurity Framework for strategic governance [13, 14], delivering executive visibility, measurable progress, vendor accountability, and regulatory compliance readiness.

How bitsIO Enables Proactive OT Security

As a Splunk partner, bitsIO brings deep industrial expertise combined with proven implementation methodology. Rather than treating OT security as purely a technology deployment, bitsIO approaches it as an integrated transformation connecting security, operations, and business outcomes.

Unified Visibility Across IT and OT:

bitsIO’s Industrial Data Intelligence Services address the fundamental challenge: data trapped in disconnected silos. By leveraging Splunk as the foundation for analytics and observability, bitsIO enables comprehensive visibility serving both security and operational objectives. Security teams detect threats across converged environments while operations teams investigate production issues and optimize performance—all from the same platform.

Structured Implementation:

bitsIO applies a phased approach, delivering value quickly while building toward advanced capabilities:

Discovery and Alignment: Comprehensive assessment of data sources, integrations, and visibility gaps, delivering OT and IT data mapping, ingestion design using Splunk, and alignment of KPIs to business goals.
Contextualization and Visualization: Contextualized visualizations unify production, maintenance, quality, and security data through Splunk dashboards, enabling teams to correlate equipment status, operator activity, process events, and security signals.
Operational Intelligence Enablement: Training plant personnel, engineers, and managers to conduct investigations directly within Splunk, empowering users as active investigators who identify issues and implement improvements quickly—accelerating both security incident response and operational problem-solving.
Predictive and AI Readiness: Preparing organizations for predictive analytics and AI by structuring Splunk environments around contextual logic, establishing readiness for predictive maintenance, process optimization, and AI-driven security threat detection.

Why Splunk for OT Security:

Splunk stands as a recognized leader in cybersecurity with market-leading SIEM capabilities [5]. For manufacturing, Splunk offers IT/OT SOC integration with unified security operations, a dedicated OT Security Add-On expanding visibility in OT environments, integration with leading solutions like Cisco Cyber Vision, and solution accelerators for common OT use cases [5].

Organizations working with bitsIO experience measurable improvements: reduced unplanned downtime and improved mean time to repair, increased equipment utilization while reducing process variability, and enhanced quality with faster incident response by analyzing equipment, operator, process, and security data together.

Implementation Roadmap

Discovery Phase: Deploy passive monitoring, conduct risk-prioritized assessments, map architecture, interview operational teams, and benchmark against frameworks. Outcomes include a complete asset inventory, network documentation, and a prioritized roadmap.
Foundation Phase: Implement segmentation with security zones, deploy real-time monitoring with anomaly detection, establish patch management, add multi-factor authentication, create response procedures, and integrate threat intelligence. Outcomes include segmented architecture, continuous monitoring, and trained personnel.
Advanced Phase: Deploy AI-powered detection, implement automated response, establish threat hunting, advance toward zero trust, and achieve framework compliance. Outcomes include automated capabilities, advanced maturity, reduced response times, and documented ROI.
Continuous Phase: Conduct regular assessments, update threat intelligence, evaluate emerging technologies, build security into new projects, and optimize compliance positioning.

Overcoming Common Challenges

“We can’t afford downtime”: Use passive monitoring with zero production impact, phased changes during maintenance windows, and virtual patching until scheduled updates.

“Our OT staff lacks cybersecurity expertise”: Partner with managed security providers like bitsIO with OT specialization, implement cross-training, and leverage integrated solutions.

“Legacy equipment can’t support modern security”: Implement network-level protections independent of endpoints, use compensating controls, and apply risk-based prioritization.

“Leadership doesn’t understand OT risk”: Quantify exposure in financial terms, use real industry breach examples, benchmark against competitors, and frame security as enabling transformation.

Conclusion: The Time to Act is Now

The evidence is overwhelming: reactive security has failed manufacturing. Attacks are surging at unprecedented rates, with manufacturing remaining the #1 target globally for four consecutive years. The financial impact is staggering—breach costs averaging $5.56 million, downtime reaching up to $2.3 million per hour, and annual losses totaling $255 million for the average manufacturer.

Yet the path forward is clear. 46% of manufacturers who have achieved advanced security maturity are seeing measurably better outcomes—fewer incidents, faster recovery, and the competitive advantage that comes from demonstrated resilience. They’ve recognized that OT security isn’t just about protection; it’s about enabling the visibility and intelligence needed to thrive in modern manufacturing.

The manufacturers who will lead tomorrow are those who act today—integrating security with operational intelligence, empowering their teams with real-time investigation capabilities, and building defense in depth while optimizing performance. Those who continue waiting will find themselves explaining breaches to customers and regulators instead of celebrating innovation and growth.

The window for proactive transformation is narrowing. Threats aren’t slowing down, regulations aren’t easing up, and your competitors aren’t standing still.

The question isn’t whether to invest in proactive OT security. The question is whether you’ll invest on your timeline or after an attack forces your hand.

Ready to Transform Your OT Security Posture?

bitsIO helps manufacturing organizations across the United States move from reactive firefighting to proactive resilience. As a Splunk partner with deep industrial expertise, we don’t just implement technology—we transform how you see, understand, and protect your operations.

Our Industrial Data Intelligence Services deliver:

Unified visibility across IT and OT environments using Splunk
Proven methodology that delivers value quickly while building toward advanced capabilities
Empowered teams that can investigate threats and optimize operations in real-time
Measurable outcomes in reduced downtime, faster incident response, and improved operational performance

Leading manufacturers are adopting integrated platforms that provide unified visibility across IT and OT environments:

Unified Security Platforms: Solutions like Splunk Enterprise Security with OT-specific add-ons serve as the foundation, correlating security events across both environments for holistic threat detection.
OT-Specific Tools: Specialized solutions like Cisco Cyber Vision integrate with broader platforms to provide deep visibility into industrial control systems, PLCs, and SCADA networks.
AI-Powered Detection: Machine learning algorithms that understand normal operational patterns and automatically flag deviations indicating potential security threats or equipment issues.
Network Segmentation: Tools that create secure zones between IT and OT networks, implementing microsegmentation and Zero Trust principles without disrupting operations.
Threat Intelligence: OT-specific feeds providing real-time information about threat actors, vulnerabilities, and attack patterns targeting manufacturing.

The key differentiator: Modern manufacturers build integrated ecosystems where security tools share data and insights, enabling both proactive threat hunting and rapid incident response.

Balancing security with operational stability requires a fundamentally different approach than traditional IT security:

Prioritize Availability: Safety and production uptime always come first. Security measures must be designed around this reality.
Use Passive Monitoring: Deploy network TAPs and SPAN ports that monitor traffic without sitting in the data path—complete visibility with zero production impact.
Schedule Strategically: Implement security changes during planned maintenance windows rather than forcing unplanned downtime. Virtual Patching: When systems can’t be taken offline, use network-level controls through Intrusion Prevention Systems to block exploit attempts while operations continue.
Phased Implementation: Roll out security measures incrementally—test in non-production first, then implement one line at a time.
Risk-Based Decisions: Not every security recommendation fits every OT context. Use risk assessments considering both security threats AND operational requirements.
Collaborate Early: Involve OT engineers, plant managers, and operations teams from the beginning. Security designed with their input succeeds without disrupting operations.

The philosophy: Security enables operations, it doesn’t constrain them. Proactive security actually increases operational stability by preventing the massive disruptions caused by cyberattacks.

Manufacturers face several interconnected challenges:

Cultural Resistance: IT teams understand cybersecurity but lack operational context. OT teams understand production but lack cybersecurity expertise. Breaking down these silos requires leadership commitment and cross-functional collaboration.
Legacy Systems: Equipment with 15-25 year lifecycles can’t run modern security agents, support encryption, or be patched without risking stability.
Lack of Visibility: Many manufacturers don’t have complete inventories of OT assets—unauthorized devices and undocumented systems create blind spots.
Resource Constraints: Lean operational teams are already stretched thin. Adding cybersecurity responsibilities without additional resources creates overwhelming burden.
Budget Justification: When production runs smoothly, justifying security investments is difficult. Building business cases requires translating technical threats into financial impact.
IT/OT Convergence Complexity: Digital transformation connects previously isolated systems, creating security challenges that traditional approaches alone can’t address.
Vendor Fragmentation: Dozens of equipment vendors with proprietary protocols and limited security capabilities make coordinated security difficult.

The path forward: Start with quick wins demonstrating value, building momentum and stakeholder buy-in for larger transformations.

Legacy systems present unique challenges, but practical approaches exist:

Passive Network Monitoring: Deploy solutions that observe communications without touching legacy systems. Modern platforms decode industrial protocols to identify assets and establish baselines—all passively.
Network Traffic Analysis: Analyze traffic patterns to discover undocumented assets, identify communication relationships, and detect anomalies without requiring agents or modifications.
Leverage Existing Systems: Use data already collected by historians, SCADA, and MES platforms. Bring this into unified analytics platforms for visibility and security context.
Enhanced Inventories: Start with plant engineers’ documentation, then augment with automated discovery tools that validate and expand the inventory.
Unidirectional Gateways: Hardware-enforced one-way data diodes safely extract data for monitoring without creating attack pathways back into production.
Network-Level Response: When incidents occur, focus on network-level containment—segment affected systems, block malicious traffic, implement virtual patching—rather than direct endpoint actions.
Contextual Documentation: Build runbooks documenting each system’s normal behavior, vulnerabilities, dependencies, and response procedures for faster incident decisions.
Phased Modernization: Use visibility gained to inform long-term upgrade roadmaps, prioritizing based on risk, criticality, and operational requirements.

The key principle: You don’t need to modernize everything immediately. Visibility and response capabilities can be built around legacy systems while planning eventual upgrades.

When patching isn’t feasible, manufacturers can implement effective compensating controls:

Network Segmentation: Isolate vulnerable systems in separate network segments with strict access controls. Use firewalls limiting communications to only necessary connections.
Virtual Patching: Deploy Intrusion Prevention Systems with signatures for known exploits. Virtual patches block attacks at the network level without modifying vulnerable systems.
Application Whitelisting: Allow only authorized software to execute. Even if compromised, whitelisting prevents malicious code execution.
Enhanced Access Controls: Implement multi-factor authentication for remote access, privilege access management for administrative accounts, and least-privilege principles.
Continuous Monitoring: Deploy solutions establishing behavioral baselines. Unusual activity triggers alerts for investigation, enabling rapid containment.
Physical Security: Strengthen physical access controls—locked cabinets, badge-restricted areas, surveillance— to prevent unauthorized access exploiting vulnerabilities.
Regular Backups: Ensure comprehensive, tested backup and recovery procedures. Store backups offline and immutable to prevent ransomware encryption.
Security Awareness: Train operators and engineers to recognize suspicious activity. Human vigilance becomes critical when technical measures are limited.
Layered Defense: Implement multiple overlapping controls—defense in depth means no single failure leaves you exposed.
Document Everything: Record all compensating controls, regularly assess effectiveness, and communicate residual risk to leadership for informed decision-making.

The reality: Compensating controls reduce risk to acceptable levels while maintaining operations, but they’re temporary measures. Plan for eventual system replacement or upgrades

Both agencies conduct inspections and can penalize and suspend research programs for noncompliance.

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