Why Manufacturing Needs Stronger OT Cybersecurity
According to Verizon’s DBIR Report, data breaches in the manufacturing industry rose by 89% year over year, reaching 1,607 confirmed cases compared to 849 in 2024. This is largely due to the increasing interconnection of IT and OT systems. Files such as CAD designs, predictive maintenance logs, or supplier updates now flow across both environments, creating new entry points for attackers.
When these files are compromised, the result is not just data loss but production downtime, operational disruption, and compliance risks. Because uptime is critical in manufacturing, even small incidents can escalate into supply chain delays and financial impact.
This blog highlights five strategies manufacturers are using to strengthen OT cybersecurity, illustrated with real-world deployments.
1. Securing Removable Media at Entry Points
USB drives and other portable media are still a major source of risk in manufacturing environments. Files often move between departments, contractors, and suppliers without centralized inspection, and production teams under pressure may connect devices without a security check. This leaves room for malware to reach sensitive OT systems.
A practical defense is to enforce scanning and sanitization of all removable media before it enters the network. OPSWAT solutions cover different stages of this process:
MetaDefender Kiosk™
Scans and sanitizes files before they are allowed into OT networks.
MetaDefender Endpoint™
Blocks media until security conditions are met while providing additional security benefits.
MetaDefender Endpoint Validation™
Verifies that removable media was scanned under enforced policies.
MetaDefender Media Firewall™
Inspects boot sectors and file contents before use.
A real-world example comes from Abdi Ibrahim, a global pharmaceutical manufacturer. The company initially relied on air gapping but found that portable media still posed a serious threat to sensitive data such as pharmaceutical recipes. By deploying MetaDefender Kiosk, Abdi Ibrahim now scans more than 18,000 files daily without downtime. The solution not only prevents malware but also supports regulatory compliance across its manufacturing sites.
2. Validating Third-Party Devices Before They Connect
Picture this: a contractor arrives to perform urgent maintenance on the production floor. Their laptop needs to connect to the OT network immediately to get systems back online. Under pressure to minimize downtime, the device is plugged in without verification. That single decision could open the door for malware to bypass existing protections.
This scenario happens more often than most organizations realize. Vendor laptops and other third-party devices are among the most common pathways for threats to enter OT environments. Relying on trust or time pressure creates a weak point that attackers can exploit.
OPSWAT addresses this with:
™MetaDefender Drive
Scans devices to ensure they are free from malware before they gain access to the OT environment.
MetaDefender Endpoint Validation™
Confirms that devices meet scanning and sanitization requirements before access is granted.
A global automotive manufacturer faced this exact challenge. Their existing multi-vendor security setup was difficult to integrate and left gaps that exposed critical systems. By adopting OPSWAT’s platform, including MetaDefender Kiosk and visitor management integration, they gained reliable third-party device control. The result was stronger threat prevention, less downtime, and a unified process for managing external devices.
3. Transferring Files Securely Between IT & OT
File transfers are a routine necessity in manufacturing. Software updates, security patches, and design files often need to move from IT systems into OT environments. If these transfers are not properly controlled, they can bypass inspection and introduce malware into critical systems. Air gaps alone no longer provide adequate protection, since most plants now require at least some level of connectivity.
The challenge is choosing the right method for each type of transfer. OPSWAT provides multiple options, each designed for specific scenarios:
تحديات | OPSWAT Solution | المزايا |
|---|---|---|
Routine file transfers between IT and OT | MetaDefender Managed File Transfer™ | Automates and secures transfers by rescanning each file with advanced threat prevention |
One-way data flow required for monitoring or compliance | MetaDefender NetWall® [Optical Diode] | Enforces unidirectional data movement to protect OT from inbound threats |
Manufacturers around the world are applying these approaches. A Vietnamese chemical manufacturing company operating a flat, unsegmented network used MetaDefender Optical Diode to create a hardware-enforced one-way link. This eliminated communication vulnerabilities between IT and OT while maintaining operational stability.
A Fortune 500 petrochemical company took a similar path when their firewalls reached end of life. They replaced them with OPSWAT Optical Diodes, which significantly reduced the risk of inbound attacks, ensured regulatory compliance, and established long-term stability for the company’s critical systems.
4. Centralizing Cybersecurity Operations & Management
In many manufacturing organizations, each site handles cybersecurity in its own way. One plant might have a scanning kiosk, another might rely on antivirus software, and a third may lack clear processes altogether. This fragmentation makes it hard to enforce policies consistently, respond to incidents, or prepare for audits.
Centralizing operations solves this problem. With My OPSWAT Central Management, security teams can manage enrolled devices, enforce endpoint security policies, and monitor data flows from a single platform. This visibility is essential in complex environments where multiple plants, contractors, and devices are involved.
المزايا الرئيسية
- Consistent policy enforcement across all sites and endpoints
- Real-time visibility into device usage and access patterns
- Simplified compliance reporting with centralized audit logs
- Faster incident response due to unified monitoring
By consolidating security management, manufacturers not only reduce complexity but also strengthen their ability to maintain uptime and regulatory compliance.
5. Aligning with International Compliance Frameworks
Manufacturers must operate under multiple regulatory frameworks that govern cybersecurity, data integrity, and operational safety. Passing an audit requires clear evidence of controls, but relying on spreadsheets and fragmented logs makes this difficult. Aligning with recognized standards ensures both compliance and stronger resilience against threats.
Common frameworks include:
- ISO 27001 for information security management
- IEC 62443 for industrial control system security
- NIS2 Directive for European essential services, including manufacturing
- GDPR for data protection and privacy
- FDA cGMP and FSMA for food and pharmaceutical manufacturing
OPSWAT solutions support compliance by providing centralized policy enforcement, traceable logs, and secure data flow controls.
A global agriculture and food manufacturer faced this challenge when it air-gapped IT and OT systems to protect critical processes. While secure, this prevented business teams from accessing the OT data needed for planning. By deploying MetaDefender Optical Diode™, they enabled unidirectional data flow from OT to IT. This protected vulnerable OT assets, gave teams real-time visibility, and helped the organization meet FDA and FSMA requirements.
Building Cyber Resilience in Manufacturing
The manufacturing sector continues to be one of the most targeted by cyberattacks, and the risks extend beyond data to production uptime and worker safety. The five strategies outlined here show how manufacturers can strengthen resilience against these threats.
These are not just theories. Companies across the automotive, pharmaceutical, petrochemical, and agriculture sectors are already applying OPSWAT solutions to secure their operations, keeping production seamless today and ready to handle tomorrow’s demands.
Ready to learn more?
To explore these real-world deployments in greater detail, download our eBook Proven Deployments in Manufacturing.
