The Manufacturing Of Yesterday vs, The Manufacturing Of Today
Manufacturing of yesterday in India relied on manual oversight, mechanical processes and siloed systems, where consistency and uptime were the top priorities. Today, under the push initiatives like Make in India, factories are rapidly transforming into digitally connected ecosystems powered by SCADA, PLCs, IoT devices and real-time analytics. In this journey, everything from shop-floor sensors to supply chains has been reimagined, fueling India’s rise as a global manufacturing hub and setting the stage for all the changes shown below:
The Manufacturing Of ‘Yesterday’ | The Manufacturing Of ‘Today’ |
Simple physical sensors and analog gauges, manually read and tied to single machines | Smart sensors deployed on many machines across entire plant, with frequent or continuous reporting |
Fixed automation (relay logic, basic PLCs) with manual oversight and no real-time remote control | Distributed PLCs + SCADA + Remote & Mobile Operator Dashboards + Real-Time Control & Feedback Loops |
Data collected periodically + Limited historical records + Reactive maintenance | Large volumes of streaming data + Predictive maintenance + Anomaly detection + Digital twins + Real-time dashboards + AI/ML for optimization |
Mostly on-premises wired connections with isolated machines, local networks and limited external connectivity | Highly connected IIoT with wired & wireless networks and hybrid clouds, creating connectivity between factories, suppliers and remote sites |
Manual inspections + Scheduled downtimes + Reactive maintenance after faults or breakdown | Preventive & predictive maintenance with automated alerts, remote diagnostics, continuous health monitoring and minimized downtime |
Few machines connected, few sensors per machine and mostly standalone lines | Multiple lines connected, many sensors per machine and connected devices in the thousands, if not more |
Security was often considered to be physical (locks, access, etc.), with cyber risk being a low concern | Cyber risk is front and centre, with connected networks opening doors to remote access from attackers |
When The Factory Got Smart, The Attack Surface Got Better
This connectivity unlocked predictive maintenance, higher throughput and remote operations – but it also multiplied entry points, broadened attacker opportunities and blurred the lines between IT and OT.
Attackers are increasingly taking advantage, and the situation is even more heightened in India: according to a recent Fortinet report, 55% of smart manufacturing firms in India reported more than 6 intrusions in the last year, a drastic uptick from 11% the year before. Recently, several Indian industrial entities were forced to halt operations due to successful cyber threats, underscoring the dire consequences of such events.
The Importance Of Getting IT-OT Convergence Right
In the same Fortinet report, it is mentioned that one of the key drivers in this steep rise in manufacturing-centric cyber intrusions is the current convergence of IT & OT networks that many enterprises in the sector are undertaking. This integration, at its core, makes perfect business sense – linking IT & OT enables real-time visibility across the factory floor as well as corporate operations, helping enterprises optimize operations, reduce downtime and improve product quality.
The problem is, many enterprises are leaving gaps while undertaking this convergence, and that can lead to debilitating consequences such as lateral movement from IT to OT, exposure of legacy protocols to the Internet and cascading risks that can halt production or damage physical assets.
The reality is that IT & OT must be integrated in a way where they work in complementary ways. Done wrong, it creates blind spots that attackers exploit – done right, it amplifies the best qualities of both:
IT Strengths | OT Strengths | Optimized Factory |
Data Protection & Encryption | Supply Chain Visibility | Secure, Transparent Operations |
Identity & Access Management | Process Control & Uptime | Trusted, Resilient Factory Floor |
Compliance & Auditability | Real-Time Production Metrics | Regulatory-Aligned Productivity |
Threat Detection & Incident Response | Safety Systems & Physical Reliability | Fast, Safe Recovery From Threats |
Cloud Scalability & Analytics | IoT + SCADA + PLC Data Streams | Predictive Insights With Secure Data Flow |
Securing Today’s Factory Floor With iValue’s Industrial Security Stack
Unlike other digital stack providers in the market, iValue’s Manufacturing/Industrial Security Stack is designed specifically for the unique requirements of industrial environments. What sets our stack apart is its ability to safeguard operations while optimizing performance, ensuring both zero downtime and uncompromised safety.
The result is a comprehensive, layered architecture for the modern factory floor – holistically provided by our industry-leading OEMs:
provides next-gen firewalls and threat prevention for industrial networks, ensuring segmentation and blocking of sophisticated malware campaigns | brings industrial vulnerability management, continuously assessing OT assets and exposing risks before adversaries can exploit them |
offers high-performance, secure switching & networking that provides scalable, deterministic connectivity across factory networks | Trellix forms the building blocks for advanced threat intelligence and incident response, helping detect and respond to zero-day and targeted OT attacks |
for data security and insider threat protection, mitigating risks from both malicious insiders and human error in sensitive environments | brings DDoS mitigation and edge security, shielding industrial control networks from volumetric and application-layer attacks |
Imperva protects applications and APIs, preventing attackers from exploiting web-facing portals linked to industrial systems | Netscout sets processes for deep packet inspection and network visibility, ensuring continuous monitoring across IT & OT traffic flows |
Akamai ensures content delivery and web application firewalling, securing cloud-based industrial platforms and remote operator access | A10 Networks provides application delivery and secure load balancing, ensuring reliability and uptime for mission-critical industrial apps |
Riverbed facilitates network performance optimization, enhancing visibility and performance across distributed factory sites | Algosec undertakes policy orchestration and firewall management, automating compliance and reducing misconfiguration risks in complex hybrid environments |
Ivanti manages your endpoints and patches, securing industrial devices and ensuring even legacy endpoints stay updated and hardened | Array Networks secures remote access & SSL VPNs, enabling safe connectivity for third-party contractors and field engineers without exposing OT assets |
A Stack That Works In Sync To Create Seamless IT-OT Convergence
What sets our stack apart is the fact that it doesn’t just secure OT environments in isolation: it bridges IT and OT, enabling manufacturers to extract maximum value from integration while minimizing cyber risks. Each OEM contributes vitally to this balance, creating a fabric where IT and OT objectives are mutually inclusive rather than conflicting:
Mutually Inclusive IT & OT Objectives | |
Protecting Data Across Boundaries
| Ensuring Uptime & Reliability
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Visibility & Risk Management
| Resilience Against Modern Threats
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- Optimized operations without compromising security
- Data-driven insights with protected flows across IT and OT
- Seamless regulatory compliance that doesn’t slow down innovation
- Resilience against cyberattacks that target both digital and physical assets