Why Cybersecurity for Operational Technology (OT) Can’t Be Ignored in Manufacturing

Your machines don’t just make products—they also generate data, connect to networks, and depend on software. This convergence of IT (Information Technology) and OT (Operational Technology) has unlocked huge efficiencies, but it’s also opened the door to cyber threats that didn’t exist a decade ago.

If you’re not actively protecting your OT systems, you’re putting your productivity—and profitability—at serious risk.

What Is Operational Technology (OT), and Why Does It Matter?

OT includes any hardware or software that monitors or controls physical processes—think CNC machines, SCADA systems, HMIs, PLCs, robotics, and more.

These systems used to operate in isolation. But now they’re increasingly connected to enterprise networks, cloud platforms, and the internet for:

• Real-time monitoring and analytics

• Predictive maintenance

• Remote access and diagnostics

• Automated quality control

While this connectivity drives efficiency, it also creates new attack surfaces that traditional IT security tools don’t fully address.

Why Manufacturers Are Prime Targets for Cyberattacks

Manufacturing has become one of the top targeted industries for ransomware and cybercrime. Why?

• Legacy systems with outdated software are common

• Minimal segmentation between IT and OT networks

• Limited visibility into industrial control traffic

• High cost of downtime makes manufacturers more likely to pay ransoms

• Supply chain interconnectivity exposes weak links

A single unpatched PLC or improperly secured remote access point can bring an entire line to a halt—or worse, compromise safety.

OT vs IT Cybersecurity: What’s Different?

While IT cybersecurity focuses on data integrity, OT security is about process continuity and physical safety. Here’s a quick comparison:

This is why OT environments require a specialized cybersecurity strategy—not just a copy of your existing IT playbook.

Key Cybersecurity Best Practices for OT Environments

1. Network Segmentation

Separate your IT and OT networks. This prevents threats from jumping between systems.

Example: A phishing attack on a front office email shouldn’t be able to reach your production floor.

2. Asset Inventory & Visibility

You can’t secure what you don’t know about. Use tools to map all connected OT devices and protocols.

• Identify legacy systems

• Monitor network traffic patterns

• Detect unauthorized devices

3. Access Control & Authentication

Limit who can access OT systems, and how.

• Require strong, unique passwords for PLCs and HMIs

• Disable unused ports and services

• Use MFA for remote access, especially for vendors

4. Patching & Virtual Protection

Many OT devices can’t be easily patched. Use virtual patching techniques—such as intrusion prevention systems (IPS)—to block known exploits.

5. Industrial-Focused Monitoring

Standard antivirus isn’t enough. Use specialized OT monitoring tools that:

• Understand industrial protocols (Modbus, OPC, etc.)

• Detect abnormal behavior from machines

• Alert on anomalies without disrupting operations

6. Vendor Risk Management

Third-party vendors often need access to your OT systems. Ensure:

• Secure remote connections (VPNs, zero trust)

• Logging of all vendor activities

• Revoking credentials when not needed

7. Incident Response Planning

Have a plan tailored to your production floor.

• Who shuts down a line in a breach?

• What systems take priority in recovery?

• How fast can you restore operations from backup?

You don’t want to be building this playbook during a crisis.

Real-World Impact: The Cost of Inaction

In 2024, a Midwest plastics manufacturer suffered a ransomware attack after a technician used an old remote desktop tool on a connected HMI.

• Downtime: 3 days

• Lost revenue: Over $400,000

• Response: Full OT network rebuild, plus 8 weeks of forensic analysis

• Root cause: No MFA, poor segmentation, and unmonitored remote access

These stories are becoming more common—and they’re entirely preventable.

How Andromeda Technology Solutions Helps Protect OT Environments

We work with Midwest manufacturers every day to strengthen cybersecurity on both IT and OT fronts. Our team delivers:

✅ Industrial network segmentation and firewall deployment
✅ 24/7 focused monitoring
✅ Secure remote access for vendors and technicians
✅ Risk assessments and compliance audits
✅ Custom incident response planning for your facility

We understand the unique needs of production environments—and we’ll never compromise uptime for the sake of generic security.

Ready to Secure Your Plant? Let’s Talk.

Cyber threats to OT environments aren’t going away—but with the right strategy, you can stay protected and productive.

Schedule your OT cybersecurity assessment today.
Visit andromeda-tech-solutions.com/contact or call (815) 836‑0030 to speak with one of our industrial IT specialists.