The line between Information Technology (IT) and Operational Technology (OT) has been blurring for years and what once were two distinct realms — IT managing data and networks, and OT controlling physical processes on the production floor — are now converging to drive smarter, more efficient manufacturing.
However, according to Trustwave SpiderLabs just released Manufacturing Sector Deep Dive: Convergence of IT/OT, a companion piece of research to the 2025 Trustwave Risk Radar Report: Manufacturing Sector, these more modern manufacturing opportunities and capabilities come with many new risks.
The power of IT/OT integration and the world that it is delivering is called Industry 4.0, also dubbed the Fourth Industrial Revolution. Industry 4.0 is using digital technologies to transform manufacturing through increased efficiency and productivity, creating a more flexible manufacturing environment, enabling more intelligent decision-making, creating smart factories, and generally improving the quality of what is being produced.
But There's a Catch: Rising Cyber Threats
As manufacturing environments become more connected, they also become more vulnerable. Traditional OT systems weren’t built with cybersecurity in mind, and while IT professionals are well-versed in daily cyber hygiene, many OT teams are still catching up.
This oversight can lead to serious consequences: The NIST 2024 Annual Report found that cyberattacks cost U.S. manufacturers between $8.3 billion and $36.3 billion last year alone.
Threats Old and New
The report covers how traditionally OT environments have been more susceptible to cyberattacks due to built-in, but undiscovered, vulnerabilities, lack of updates and inconsistent patch releases, and limited integrated security controls.
These issues leave OT systems predisposed to ransomware and supply chain attacks, allowing an attacker to more easily gain lateral movement once initial access is obtained.
Trustwave SpiderLabs does not leave manufacturers out in the cold. The report includes an exhaustive list of mitigations for specific issues along with actionable recommendations for senior leadership, CISOs, and security and IT/OT Managers to help create a secure and resilient environment.
As the threat landscape for OT rapidly grows, these environments are increasingly vulnerable, making the challenge of modernizing and securing these systems even more pressing.
Please download the Manufacturing Sector Deep Dive: Convergence of IT/OT report for all the details and its companion pieces:
