Top OT Security Challenges and How to Address Them

Challenge #1: Gaining Comprehensive Asset Visibility

If you’ve spent even a day on the production floor, you already know how many devices are in play—plus countless others you might not spot right away. And when you don’t see every device, how can you protect them all?

• Hidden Entry Points: Sometimes, someone hooks up a piece of equipment “just to test” and forgets to inform security teams. That device then slips under the radar.

• Gaps in Real-Time Monitoring: If your OT environment lacks continuous oversight, you could miss unusual spikes in traffic or unauthorized logins until it’s too late.

• Difficult Diagnostics: Without a comprehensive map, troubleshooting a suspected breach feels like searching for a single misplaced bolt in a vast warehouse.

Practical Ways to Improve Visibility

• Industrial-Grade Discovery: Traditional IT scanning tools may skip over older or proprietary OT protocols. Specialized solutions designed for industrial environments do a better job of locating every device, both new and old.

• Ongoing Network Surveillance: Keep an eye on day-to-day communication among your equipment. Any anomalous patterns or unexpected bursts of data can raise red flags.

• Unified Dashboard: When you centralize all that monitoring data, everyone—from floor managers to IT security—benefits from a shared, up-to-date view.

Challenge #2: Managing Legacy Systems

In plenty of plants, older machines still serve as a backbone for production. Unfortunately, those same systems may also be the least prepared to deal with modern cyber threats. They were built for stability, not for advanced security.

• Well-Known Vulnerabilities: Attacks that exploit outdated software are widely documented, making older systems tempting targets.

• Inherent Compatibility Issues: You can’t simply tack on encryption or multi-factor authentication if the hardware isn’t equipped to handle it.

• Limited Support: As vendors discontinue products, you might find yourself scavenging for spare parts, custom patches, or niche expertise—often at a steep cost.

A Balanced Approach

• Identify Critical Assets: First, figure out which legacy devices affect safety or productivity the most. Target those for upgrades or extra protective measures.

• Look for Maintenance Windows: Plan incremental modernization during scheduled downtime so you don’t wreak havoc on daily operations.

• Segment Where Possible: If an immediate replacement isn’t on the table, isolate high-risk devices on their own network segments, reducing the chance of lateral attacks.

Challenge #3: Bridging the IT/OT Divide

IT pros see the world through data confidentiality and software patches. OT teams focus on uptime, worker safety, and consistent production. It’s not hard to see how these differing viewpoints might clash.

• Misaligned Priorities: A quick software patch might be child’s play for IT, but a single system reboot can halt an entire line on the OT side.

• Gaps in Knowledge: Many IT folks aren’t familiar with SCADA protocols or industrial controllers, and OT veterans may not have the latest cybersecurity training.

• Communication Stumbles: Without a shared language or framework, both sides might struggle to coordinate on a response plan for potential attacks.

Finding Common Ground

• Collaborative Risk Assessments: Sit everyone at the same table—literally or figuratively—to map out possible threats and weigh their impact on both data and uptime.

• Cross-Team Training: Give OT personnel some cybersecurity fundamentals, while IT staff gets a guided tour of the plant floor. More empathy, fewer misunderstandings.

• Workflow-Ready Tools: Seek security solutions built specifically for industrial needs, and consider bridging them with IT’s existing platforms where it makes sense.

Bringing It All Together: A Holistic OT Security Program

Many organizations are discovering that a comprehensive, structured approach can tie together these multiple OT challenges in a cohesive way. By uniting asset visibility, prioritized risk remediation, and incident response into one overarching program, you create a more efficient route to robust security.

Core Elements of a Holistic OT Framework

• Thorough Asset Inventories 

  First, make sure that you know exactly what’s on your network: which devices are connected, how they communicate, and who’s responsible for them. An accurate inventory sets the stage for everything else.

• Risk-Based Action 

  Some threats require an immediate fix, others can wait for the next downtime window. If you can’t patch a device right away, look into offsetting controls—such as network segmentation or stronger access rules—to keep potential attacks in check.

• Unified Incident Playbooks

  Clearly map out who does what if a breach or other disruption occurs. Identifying concrete steps in advance often means the difference between quickly containing a threat and letting it escalate.

• Shared Visibility

  Many holistic programs offer a unified dashboard, enabling both OT and IT teams to spot issues in real time. When everyone’s looking at the same data, collaboration flows more smoothly.

• Local Control with Central Guidance 

  Each plant or site can typically manage its day-to-day security, while corporate or regional leadership maintains an overall view. This balance helps ensure that local needs are met without losing sight of enterprise-wide goals.

In Practice

Consider a North American utility company that once juggled legacy systems, newer equipment, and scattered tools for asset management. By embracing a more cohesive OT security program—supported by Verve® by Rockwell Automation—they experienced several benefits:

• Unified Their Inventory 

  Every device, from the oldest breaker to the newest smart controller, was cataloged under a single source of truth.

• Reduced Downtime

  With real-time insights into vulnerabilities, they could plan software updates to align with maintenance windows, cutting back on unexpected outages.

• Bridged IT and OT Cultures 

  Both departments rallied around consistent workflows and playbooks, reducing miscommunication and lowering the chance of critical oversights.

The Path Forward

Strengthening visibility, protecting your legacy gear, and facilitating better IT/OT cooperation are all significant steps toward improved OT security. As threats evolve, so does the need for a unified approach that ties these strategies together and supports smooth, safe operations.

Rockwell Automation remains ready to connect technology with human expertise, helping you sustain innovation without sacrificing security. When you integrate a comprehensive, structured plan for OT security, you build a sturdier foundation against potential risks—one that can keep pace with your organization’s growth.