The threat landscape for Operational Technology (OT) environments, particularly in the manufacturing sector, is more severe than ever. At the recent SecureWorld Manufacturing & Retail Virtual Conference, industry leaders Matthew Burroughs, CISO of Novolex; Florian Doumenc, CEO of Trout Software; and Chris Duffey, Industry Technical Specialist Lead at Splunk, came together to explore the evolving cybersecurity challenges facing OT systems. Their discussion underscored the increasing complexity of these threats, from ransomware attacks to phishing schemes, and emphasized the critical need for visibility, cross-functional collaboration, and a proactive security strategy.

As digital transformation accelerates, operational technology (OT) environments are becoming more exposed to cyber threats. The convergence of IT and OT systems has expanded the attack surface, making OT networks a more attractive target for cybercriminals. As Matthew Burroughs explains, “The traditional boundaries between IT and OT are disappearing, necessitating a complete rethink of how we secure these environments.”

Attackers are constantly refining their tactics to exploit vulnerabilities within OT systems, posing severe risks to organizations that are slow to adapt. Florian Doumenc highlights the urgency: “a single breach can lead to significant production downtime and financial loss, underscoring the need for a more robust security posture.”

To address these risks, organizations must adopt a proactive approach, implementing advanced monitoring, real-time threat detection, and zero-trust security architectures tailored to the unique needs of OT environments.

Click Here to watch back the webinar On-Demand.

The panelists highlighted several key trends shaping OT security in manufacturing:

Increased Cyber Attacks on OT Systems:

The frequency and sophistication of attacks targeting OT systems are rising sharply. According to the 2023 SANS State of OT/ICS Cybersecurity Report, 70% of OT organizations experienced a security incident in the past year, with 43% of those incidents involving ransomware. Cybercriminals are leveraging advanced persistent threats (APTs) to gain long-term access to critical infrastructure, increasing the potential impact of each breach. The Verizon 2023 Data Breach Investigations Report further highlights that 29% of breaches in OT environments are attributed to state-affiliated actors, who often use APT tactics to infiltrate and remain undetected within critical systems.

Greater Focus on Zero-Trust Security Models:

The panel emphasized the critical need for adopting a zero-trust architecture. As Matthew Burroughs, CISO of Novolex, noted, “Zero-trust is no longer optional in OT environments; it’s an essential strategy to minimize the attack surface.” This model assumes that every network segment, device, and user could be compromised, requiring strict verification for all access attempts. "Zero-trust is crucial for OT environments because it helps ensure that even if one part of the network is compromised, the rest remains protected. It's about building barriers within your network to prevent lateral movement by attackers," said Trout's Florian Doumenc. The global zero-trust security market is expected to grow from $19.6 billion in 2022 to $51.6 billion by 2027, reflecting the increasing adoption of this model as organizations recognize the need for stringent security protocols.

Growing Importance of Real-Time Visibility:

Real-time visibility into OT networks is crucial for detecting and responding to threats quickly. Chris Duffey, Industry Technical Specialist Lead at Splunk, stated, “You can’t protect what you can’t see.” Advanced monitoring tools using AI and machine learning (ML) are becoming essential to analyze network traffic and user behavior for potential security incidents. A study by Gartner predicts that by 2025, 60% of OT security solutions will integrate AI and ML to identify security incidents more accurately. This aligns with findings from the Ponemon Institute, which indicates that companies with real-time visibility tools in place can reduce the average time to detect and contain a data breach by up to 58%.

While the need for enhanced OT security is clear, many organizations face challenges in implementing these measures effectively:

Integrating Legacy Systems:

Many OT environments rely on outdated systems that lack modern security features. Chris Duffey highlighted, “Legacy systems pose one of the biggest security risks." Upgrading these systems is costly and can disrupt operations, requiring creative solutions like compensating controls or network segmentation.

Cultural Barriers Between IT and OT Teams:

Differences in priorities between IT and OT teams can create friction. IT teams focus on data security, while OT teams prioritize safety and continuous production. “We’re seeing more organizations build cross-functional teams that bring together OT engineers and IT security experts to foster a holistic approach to cybersecurity,” noted Florian Doumenc.

Budget Constraints:

Allocating sufficient funds for OT cybersecurity can be challenging, particularly when security is seen as an expense rather than an investment. Burroughs explained, "We're seeing a shift in where the money is going. More organizations are investing heavily in securing their OT environments," but IT leaders must still build a compelling business case to justify these costs.

Maintaining Continuous Operations:

Security upgrades can require system downtime, which may disrupt production. IT leaders must carefully plan and implement upgrades to minimize operational impacts, using non-disruptive security technologies where possible.

The panelists offered several actionable recommendations for IT leaders looking to bolster their OT security posture:

Adopt a Zero-Trust Architecture:

Enforce strict verification processes for all access attempts to reduce the risk of lateral movement by attackers. Matthew Burroughs emphasized, "By deploying zero-trust principles, IT leaders can ensure that even if a breach occurs, the potential damage is contained to the smallest possible area."

Evaluate Legacy Systems:

Assess which legacy systems pose the highest risks and develop a plan to either modernize or protect these systems with additional security controls. “Older systems are often the weakest link; they were never designed with today’s threats in mind,” noted Chris Duffey. This could include implementing compensating controls, such as network segmentation or enhanced monitoring, to secure vulnerable assets until they can be replaced.

Segmentation:

Isolate critical OT systems from IT networks to prevent lateral movement by attackers. Florian Doumenc stressed, “Segmentation is critical to limit the reach of an attacker if they do get in. It’s about containing damage before it spreads.”

Enhance Cybersecurity Training:

Regularly educate employees on the latest cyber threats, including phishing and social engineering tactics. “Human error is still a leading cause of breaches. Continuous education can help reduce these risks significantly,” remarked Matthew Burroughs.

Invest in Advanced Monitoring Tools:

Deploy monitoring tools that provide real-time alerts and use AI-driven analytics to detect anomalies. “Automated tools can quickly identify patterns that human analysts might miss, offering an additional layer of defense,” said Chris Duffey.

Develop an Incident Response Plan:

Create a detailed incident response plan tailored for OT environments to ensure rapid containment and recovery when a breach occurs. Florian Doumenc noted, “Preparation is key. The faster you can respond, the less damage will be done.”

Organizations are reallocating resources to better address the growing threats to OT environments. This includes:

Increased Budget Allocation:

More organizations are investing heavily in OT cybersecurity, recognizing the potential impact of a cyber incident on their operations. Matthew Burroughs noted, "We're seeing a shift in where the money is going."

Investment in Specialized Tools:

Resources are being directed toward OT-specific tools that provide real-time visibility and threat detection. As Chris Duffey emphasized, “Real-time visibility into OT networks allows for faster detection and response to threats, which is critical in minimizing the impact of an attack.”

Formation of Cross-Functional Teams:

To manage OT cybersecurity effectively, many organizations are forming cross-functional teams that combine IT and OT expertise, fostering a holistic approach to cybersecurity. Florian Doumenc added, “Cross-functional teams are essential for a comprehensive security strategy.”

Adapting to Stay Ahead of Cyber Threats

The SecureWorld webinar highlighted the critical need for manufacturing organizations to evolve their OT security strategies in response to an increasingly complex threat landscape. As digital transformation accelerates and the convergence of IT and OT systems expands the attack surface, it is imperative for organizations to adopt a proactive, defense-in-depth approach. By implementing zero-trust architectures, improving network visibility, upgrading legacy systems, and fostering collaboration across IT and OT teams, IT leaders can build a more resilient cybersecurity posture that is equipped to face emerging threats.

How Trout Software Can Help

Trout Software provides robust, plug-and-play solutions tailored to the unique cybersecurity challenges in OT environments. With the innovative Demilitarized LAN (DLAN) technology, Trout’s Secure Network Overlay enables rapid deployment and seamless integration with existing legacy systems, minimizing disruptions to ongoing operations. The DLAN technology offers real-time visibility, enforces zero-trust principles, and creates secure network boundaries that isolate critical assets from potential threats.

These capabilities allow organizations to quickly gain actionable insights into network traffic, detect threats faster, and foster better collaboration between IT and OT teams. By simplifying security management and enhancing the protection of critical infrastructure, Trout helps companies stay ahead of evolving threats and maintain secure, uninterrupted operations.

Discover how Trout’s DLAN technology can support your organization’s journey to a stronger OT security posture and compliance readiness.

Watch the On Demand Webinar in Full Below 👇