Get Your Free Risk Report Today
  1. Home
  2. /
  3. Resources
  4. /
  5. Blogs
  6. /
  7. Securing the Factory Floor...

Securing the Factory Floor with IT-OT Convergence and Industrial Cybersecurity

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:

Checkpoint

provides next-gen firewalls and threat prevention for industrial networks, ensuring segmentation and blocking of sophisticated malware campaigns

Tenable

brings industrial vulnerability management, continuously assessing OT assets and exposing risks before adversaries can exploit them

Arista

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

Forcepoint

for data security and insider threat protection, mitigating risks from both malicious insiders and human error in sensitive environments 

Cloudflare

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

  • Checkpoint and Forcepoint ensure identity, access and data protection for industrial data flows between IT systems & OT devices
  • Imperva and Akamai extend protection to applications, APIs and remote access portals, making external connectivity safe

Ensuring Uptime & Reliability

  • Arista and A10 Networks provide high-performance, resilient networking and load balancing, ensuring industrial processes remain uninterrupted
  • Riverbed optimizes performance across distributed factory sites, keeping digital operations smooth

Visibility & Risk Management

  • Tenable continuously identifies vulnerabilities in OT assets, while Netscout provides deep visibility into IT-OT traffic flows
  • Algosec ensures compliance and firewall policy orchestration across hybrid environments 

Resilience Against Modern Threats

  • Trellix delivers advanced threat detection and incident response, bridging the IT SOC with OT operators
  • Cloudflare and Ivanti provide edge security, DDoS protection and endpoint hardening for distributed IIoT devices
  • Array Networks secures remote contractor access, a critical IT-OT touch point often exploited by attackers 
In an industry that is constantly in flux iValue’s Manufacturing Security Stack helps manufacturers gain:
  • 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
If this is the ideal IT-OT convergence you’re looking to achieve in your factories, click here to speak to an iValue security expert today.

Authored by

Similar Posts

Scroll to Top