Industry 4.0 has completely transformed the way information technology (IT) and operational technology (OT) teams operate. Traditional machinery now coexists with cloud platforms, and real-time data collection clashes with decades-old legacy infrastructure. This IT/OT convergence is redefining how manufacturers operate and secure their environments, promising smarter factories, optimized process controls, and sophisticated predictive maintenance.
But these benefits come at a cost. IT/OT convergence also introduces new risks and increases the possible attack surface, especially for OT systems that are accustomed to the security of isolation. Fortunately, AI has emerged as a powerful ally in managing both the benefits and threats that IT/OT convergence inevitably brings.
Closing The IT/OT Divide
IT and OT have been historically siloed, but rising demands for efficiency, real-time data visibility, and continuous monitoring have driven OT online. Now, manufacturers worldwide are rapidly converging their IT and OT networks to improve their data management and sharing, encourage collaboration, and bridge communication gaps. In fact, 70 percent of OT systems are predicted to be connected to corporate IT networks by next year.
However, to maintain security and operational continuity amid cyber threats, OT must be able to run on air-gapped networks isolated from the internet. Recent initiatives to modernize dated industrial facilities and integrate IT/OT are not prioritizing air gap security and are therefore exposing industrial control systems (ICS) and manufacturing environments to greater risk.
The Risks of Operational Convergence
While 86 percent of the manufacturers believe IT/OT integration can provide better business outcomes, only 19 percent of them have reached an advanced level in securing their combined environments. This disconnect is more than a growing pain; it’s a critical vulnerability.
IT/OT cyber risks have been evident for years, as seen in the 2021 Colonial Pipeline attack where attackers exploited IT systems to disrupt OT operations, leading to widespread fuel shortages across the U.S. East Coast. As more legacy machinery is connected to modern platforms, these types of attacks will only continue to run rampant, causing large-scale damage and disruption.
Cybercriminals are targeting the blind spots that exist because IT and OT teams, who often operate under different protocols. IT prioritizes data integrity and may not fully understand the nuances of manufacturing operations, while OT focuses on ensuring operational and business continuity. These differing priorities lead to inconsistent security postures and limited collaboration on threat mitigation. A lack of shared expertise can delay threat detection and response, and without a unified approach to cybersecurity, attackers are increasingly able to exploit these vulnerabilities.
By the end of this year, half of all manufacturers and utilities will converge their cybersecurity and operations security functions under a unified CISO role, emphasizing the need for cohesive oversight in increasingly integrated environments. This requires IT and OT teams to step away from their usual siloed thinking and work together to create holistic strategies that prioritize cyber resilience.
The Gamechanger
As manufacturers continue to navigate this complex transition, backup and recovery should be top-of-mind. Cyber-attacks are becoming increasingly damaging: the average recovery time for critical infrastructure organizations post-cyberattack is more than 14 days, and unplanned downtime can cost as much as $260,000 per hour.
That’s where cyber resilience comes in. The security strategy enables organizations to unlock the full potential of connected systems while guarding against the risks introduced by expanded IoT networks, including downtime.
Cyber resilience encourages always-on monitoring of OT assets and network segmentation. In the event of a cyber-attack, the system can be isolated in real-time to contain the breach, limit its impact, and preserve continuity in core operations. Additionally, during backups, only the most critical data is recovered rather than restoring entire systems. This can improve incident response times from hours or days to minutes.
IT/OT convergence is reshaping the manufacturing landscape, bringing with it the promise of smarter, more efficient operations, but also greater complexity and risk. For manufacturers, the challenge will be how effectively they manage this dual reality, ensuring they work together to maintain business continuity.
Cyber resilience ensures that manufacturers can maintain the continuous uptime essential to their operations while fostering an environment of trust and reliability between IT and OT teams. From segmenting networks to accelerating threat response, the approach allows organizations to transition from solely preventative measures to a security foundation with robust backup and recovery.
Those who proactively integrate the security approach into their convergence strategies will be better equipped to navigate the challenges ahead, protect their critical systems, and take advantage of the benefits of Industry 4.0. In the era of IT/OT convergence, manufacturers must start to view cyber resilience as both an essential line of defense, and the driver of innovation.
