In recent years, Operational Technology (OT) has rapidly evolved from isolated, air-gapped systems to complex, interconnected networks integral to the manufacturing process. As a threat researcher immersed in monitoring and analysing industrial threats, I’ve seen first-hand how the convergence of OT and IT has created unprecedented opportunities and dangers for the manufacturing sector.
In this post, we’ll explore what OT really is, why it’s so critical to manufacturing, and how cyber threats are increasingly targeting these environments. Most importantly, I’ll outline what manufacturers can do to protect their operations from disruption and sabotage.
What is Operational Technology (OT)?
Operational Technology refers to the hardware and software used to detect or cause changes through direct monitoring and control of industrial equipment, assets, and processes. Unlike traditional Information Technology (IT), which deals with data, emails, and software, OT is focused on the physical processes think assembly lines, robotic arms, conveyor belts, and PLCs (Programmable Logic Controllers).
OT is the backbone of the manufacturing sector, powering everything from automotive plants to food processing facilities. It’s what makes “smart factories” tick, allowing for real-time process automation, predictive maintenance, and increased productivity.
But therein lies the issue: the more advanced and connected these systems become, the more exposed they are to cyber risk.
The IT/OT Convergence: A Double-Edged Sword
Historically, OT systems operated in isolation from corporate IT networks. But today, the drive for operational efficiency and data-driven decision-making has led to increased integration between IT and OT systems.
This convergence allows for tremendous benefits remote access, centralised monitoring, and the use of analytics and AI to optimise performance. However, it also opens up a Pandora’s box of security vulnerabilities.
Where IT networks are typically well-defended with antivirus, firewalls, and endpoint protection, OT environments have lagged behind. Many legacy industrial systems were never designed with cyber security in mind. Now, with external connectivity, they become prime targets for malicious actors.
Who’s Targeting OT—and Why?
As a threat researcher, I spend much of my time tracking actors across the threat landscape. The motivations for attacking OT in manufacturing vary:
- Nation-state actors may target industrial systems to sabotage critical infrastructure or steal intellectual property.
- Cybercriminal groups might deploy ransomware to extort payment by halting production.
- Hacktivists could attack manufacturing plants to support political causes.
- Insiders whether disgruntled employees or negligent contractors can also pose a significant risk.
A notable example is the Triton malware incident in 2017, where a safety system in a petrochemical plant was targeted. Had the attack succeeded fully, it could have led to loss of life.
More recently, ransomware variants like Lockbit, Black Basta, and Clop have specifically targeted manufacturing firms, encrypting OT systems and causing millions in downtime losses.
Real-World Consequences
A cyber attack on OT isn’t just a data breach. It can have physical, tangible consequences:
- Production outages: Downtime in manufacturing can cost thousands per minute.
- Safety incidents: If safety PLCs or HMIs are tampered with, it could put workers’ lives at risk.
- Equipment damage: Incorrect commands to machinery can cause severe mechanical failures.
- Supply chain disruption: A compromised plant can affect deliveries to multiple downstream industries.
One of the most high-profile examples is the Colonial Pipeline ransomware attack. While it was primarily an IT breach, the operational systems were pre-emptively shut down, leading to fuel shortages across the US. Imagine similar scenarios playing out across manufacturing hubs in the UK impacting energy, food, or transport sectors.
Why Traditional IT Defences Fall Short in OT
While it may seem logical to simply port over IT security measures to the OT space, there are unique challenges that make OT protection more complex:
- Legacy systems: Many OT environments run outdated software that can’t be patched or upgraded easily.
- Uptime requirements: You can’t just restart a factory PLC for updates like you can a laptop.
- Proprietary protocols: OT uses specialised communication protocols (e.g., Modbus, DNP3) not understood by traditional IT tools.
- Limited visibility: Without asset inventories and network maps, it’s hard to secure what you can’t see.
Building Resilience: Securing OT in Manufacturing
Securing OT requires a tailored, layered approach. Below are some key recommendations:
1. Asset Discovery and Inventory
Start by identifying all devices on the OT network. Knowing what’s connected is fundamental. Use passive scanning tools that won’t disrupt operations.
2. Network Segmentation
Implement robust segmentation between IT and OT networks using firewalls and demilitarised zones (DMZs). Enforce least privilege access.
3. Patch Management and Virtual Patching
Where updates aren’t possible due to vendor constraints or uptime requirements, use intrusion detection and network-based virtual patching to mitigate risks.
4. Multi-Factor Authentication (MFA)
Limit access to HMIs, SCADA systems, and engineering workstations with strong authentication controls.
5. Security Monitoring and Incident Detection
Deploy specialised OT-aware monitoring tools to identify anomalous behaviour, command injection attempts, or unauthorised access.
6. Employee Training
Operators and engineers should receive cyber security training tailored to industrial environments. Human error is still one of the biggest threats.
7. Incident Response Planning
Prepare for the worst. Develop OT-specific playbooks that address scenarios such as ransomware, unauthorised access, or process deviation.
The Role of Threat Intelligence
At the heart of effective OT cyber security is threat intelligence. By staying ahead of emerging attack trends, understanding adversary tactics, and monitoring dark web chatter, we can provide early warning and contextualise risks for industrial clients.
This intelligence can inform decisions on which systems to prioritise for protection, what attack paths are likely, and which groups are actively targeting your sector.
UK-Specific Considerations
In the UK, regulations such as the Network and Information Systems (NIS) Regulations place legal obligations on operators of essential services including manufacturers in sectors such as food, chemicals, and energy to secure their digital infrastructure.
The NCSC also provides detailed guidance and tools for managing OT risk. Leveraging these national resources is key to maintaining compliance and building resilience.
Final Thoughts
As manufacturing enters the age of Industry 4.0, cyber security must be embedded into every level of industrial operations. From sensors on the factory floor to cloud-based analytics dashboards, every component of the OT ecosystem needs to be protected.
As a threat researcher, I see daily how the threat landscape is evolving faster than ever. OT environments, once isolated and obscure, are now in the crosshairs of sophisticated attackers. But with the right strategy, mindset, and collaboration between IT and OT teams, we can stay one step ahead.
The goal isn’t just security it’s continuity, safety, and the future of modern manufacturing.
Resources:
- NCSC Cyber Assessment Framework: https://www.ncsc.gov.uk/collection/caf
- NIS Regulations Guidance: https://www.ncsc.gov.uk/collection/nis-directive
- MITRE ATT&CK for ICS: https://attack.mitre.org/matrices/ics/