Operational Technology (OT) systems — machines, robotics, control systems, Supervisory Control and Data Acquisition (SCADA), and more — are the physical heart of the manufacturing, energy, utility, and infrastructure industries. As digital transformation accelerates, those systems are no longer isolated.

The merging of Information Technology (IT) with OT, paired with developments in Artificial Intelligence (AI), cloud connectivity, edge computing, and the Industrial Internet of Things (IIoT), has brought both powerful benefits and serious risks. Building an OT cybersecurity system is no longer optional — it’s a foundational requirement for modern industrial operations.

The Changing Threat Landscape

Over recent years, manufacturers have moved aggressively toward modernization, integrating OT with IT networks to enable real-time data sharing, remote operations, and improved analytics. But that convergence has given attackers new entry points. Many adversaries are exploiting weaknesses in IT to reach OT environments that were once air-gapped. Legacy systems — devices deployed decades ago with little built-in security — are especially vulnerable as they are exposed to newer threats.

The cost of ignoring these threats is already high. One in four organizations has shut down OT operations because of cyberattacks, and critical infrastructure experienced an estimated 30% surge in cyberattacks in 2023. These breaches can cause massive financial losses and operational delays. In 2024, U.S. companies faced an average cost of $3.96 million per data breach — showing just how expensive a single incident can be for any operation.

Beyond finances, the stakes include safety, reputation, and regulatory compliance. OT disruptions can lead to physical damage, environmental harm, or even risks to human life. OT incidents often carry both physical and digital consequences, underscoring that training, risk planning, and visibility across IT and OT domains are essential.

What Makes OT Unique — And What Frameworks Must Cover

OT environments have special demands. They value availability, reliability, and safety above almost everything else. Systems must often run continuously — downtime for patching or updates can threaten production or safety. Legacy hardware and protocols may not support modern security features, sometimes making patching difficult or impossible.

Because OT and IT are now more integrated, the risks escalate. Attack vectors that begin in IT — such as phishing, vendor supply chain compromises, or insecure remote access — can move laterally into OT systems. In many organizations, the Chief Information Security Officer (CISO) now assumes responsibility for OT security, reflecting how critical the problem has become.

A solid OT security framework doesn’t treat OT like an afterthought. Instead, it embeds OT-specific governance, risk assessments, visibility, secure architecture, monitoring, vendor controls and workforce training — all tuned to the operational constraints of physical systems.

Core Elements of a Strong OT Security Framework

When constructing an OT cybersecurity system, organizations must ensure certain pillars are in place:

• Governance and leadership: Security needs executive visibility. Organizations must define ownership of OT security — aligning the C-suite, engineering, operations and IT around shared responsibilities.
• Risk assessment and asset inventory: Without a clear inventory of devices, locations, ages, and connections, prioritizing risk is impossible. Legacy equipment and vendor components often hide the biggest gaps. Risk scoring allows organizations to focus on the most urgent vulnerabilities, ensuring efforts go where they’ll have the most significant impact and steadily strengthening their overall security posture.
• Network segmentation and secure architecture: Isolate OT networks, control remote access, define demilitarized zones, and enforce strong identity and privilege controls. Minimizing unnecessary IT-OT cross-traffic reduces attack surfaces.
• Monitoring, detection, and incident response: Systems must detect anomalies early and respond quickly. OT incidents often escalate both fast and physically, so well-defined incident response plans and regular drills are essential.
• Patch management and secure configuration: Wherever feasible, update and maintain secure device configurations. Deploy compensating controls like network isolation or anomaly detection for legacy systems that cannot be patched.
• Supply chain and vendor management: Weaknesses in third-party components, Original Equipment Manufacturer (OEM) devices, firmware, or software suppliers are common vectors. Security requirements should be part of procurement and vendor contracts.
• Training, culture, and human factors: OT-centric cybersecurity requires staff who understand the digital and physical sides. Training for operators, technicians, and engineers is critical. A strong security culture ensures staff view cybersecurity as enabling safe, efficient operations rather than hindering them.

The Cost of Inaction

Neglecting OT security can lead to severe consequences. Cyberattacks can force production shutdowns, cost millions in lost output, damage machinery, harm reputation, and result in regulatory fines. Safety incidents may lead to lawsuits or worse.

Increasingly, governments are setting regulations that mandate stronger protections for OT infrastructures. Being noncompliant is no longer a liability that can be ignored — it’s a risk that can jeopardize business continuity.

Actionable Steps: What Businesses Should Do Now

For business leaders and technologists eager to protect their operations, here are practical first steps:

• Map out the OT environment: Inventory all devices, communication paths, legacy systems, and third-party links.
• Assess risk: Identify mission-critical assets and the most plausible threats, from ransomware to supply-chain compromise.
• Establish governance: Define leadership roles and create cross-functional teams bridging OT, IT, and engineering.
• Adopt proven frameworks: Use established guidelines — such as NIST SP 800-82 or ISA/IEC-62443 — to provide structure when building an OT cybersecurity system.
• Implement controls in phases: Prioritize high-risk areas first — network segmentation, secure remote access, strong identity management, and monitoring.
• Monitor, test, and refine: Conduct regular audits, drills, and reviews. Gather metrics and adjust as needed.

Secure Foundations, Confident Futures

As physical systems and digital networks converge, comprehensive OT security frameworks are essential. Understanding OT’s unique challenges, anticipating threats, and establishing strong governance, visibility, architecture, and training allow organizations to build an OT cybersecurity system that safeguards operations and people. The cost of preparation is far less than that of a breach — robust OT security is the line between vulnerability and resilience.