Managing cyber risks emerging from IT-OT convergence

The convergence of Information Technology (IT) and Operational Technology (OT) networks has certainly transformed the manner in which modern industries operate. At one level such transformations have left a deep and entrenched legacy in the generations of systems that participate in such transformations and at another they have given asset owners another efficiency and operational awareness enabler.

In simple words, this integration offers tremendous benefits including real-time data insights, operational efficiency, and predictive maintenance. On the flip side however, it also introduces a new wave of cyber risks. These risks stem from the inherent differences in technology stacks, security requirements, and operational priorities between IT and OT environments. As industries digitize their operational processes, understanding and managing cyber risks in an IT-OT integrated ecosystem becomes a critical business imperative.

Today’s blog explores the emerging cyber risks from IT-OT convergence, the underlying causes, and comprehensive strategies to mitigate these risks, while aligning with industry standards and best practices.

Don’t forget to read: How did the Jaguar Land Rover cyber incident happen? We investigate the event and offer some answers. 

What is IT-OT convergence?

IT refers to systems, hardware, and software used for information processing, data analytics, and enterprise applications. These systems prioritize confidentiality, integrity, and availability, and typically follow established security protocols like firewalls, access controls, and encryption.

OT includes systems that control physical devices and industrial processes, such as SCADA, DCS, PLCs, sensors, and actuators. OT environments emphasize real-time control, reliability, and safety. Security measures in OT are often tailored around availability and continuity, with manual overrides and redundancy.

The IT-OT convergence is the integration of these two environments to enable data exchange, automation, and enhanced decision-making. For example, connecting production equipment with enterprise systems can improve operational visibility, supply chain coordination, and performance monitoring.

However, this integration introduces systemic, process and operational complexities because OT systems were historically isolated, lacked strong authentication mechanisms, and often run legacy software. Connecting them with IT exposes vulnerabilities previously inaccessible to external attackers.

Emerging cyber risks from IT-OT convergence

Increased attack surface

When OT systems are connected to enterprise networks or the internet, the number of potential entry points expands significantly. Devices such as remote monitoring equipment, human-machine interfaces (HMIs), and wireless sensors add layers of complexity and potential vulnerabilities.

For instance, a compromised remote access tool used by maintenance staff could serve as a gateway to sensitive control systems.

Legacy systems with poor security

Many OT systems were designed decades ago with little consideration for cybersecurity. These systems may run outdated operating systems, lack encryption, and have default or hardcoded credentials.

An unpatched PLC used in a manufacturing line, for instance, could be exploited through known vulnerabilities like buffer overflows.

Inconsistent security policies

IT and OT teams often operate independently, using different policies, protocols, and tools. This disconnect or cultural discontinuity could lead to inconsistent asset management, access control, and threat monitoring.

IT security team often enforce multi-factor authentication, while OT systems rely solely on password-based access.

Insider threats

Converged networks increase the risk of insider threats, both intentional and accidental. Employees or contractors with legitimate access to IT systems may inadvertently or maliciously disrupt critical OT operations.

A technician using a personal laptop connected to the enterprise network or even an unauthorized personal hotspot could unknowingly introduce malware into OT devices.

Lack of real-time monitoring and threat detection

OT environments prioritize uptime over cybersecurity monitoring. Many organizations lack continuous monitoring tools or threat intelligence feeds tailored for industrial protocols like Modbus or DNP3.

For instance, a malware campaign exploiting a zero-day vulnerability in industrial firmware might go unnoticed until physical damage occurs.

Compliance and regulatory challenges

Regulations like NIS2, IEC 62443, and NERC CIP impose requirements on both IT and OT systems. Organizations integrating these environments must ensure compliance while managing differing standards, reporting requirements, and audit trails.

Segmentation of networks is a basic hygiene measure, every standard or regulatory mandate will have this at the core of its recommendations.  

What’s driving the risk?

· Digital transformation pressure: Organizations are integrating IoT, AI-driven analytics, and cloud solutions into operations without fully understanding the security implications.

· Remote operations: The pandemic accelerated remote monitoring and access, widening vulnerabilities across legacy infrastructure.

· Supply chain dependencies: Industrial supply chains increasingly rely on third-party vendors, remote diagnostics, and outsourced maintenance services that introduce trust gaps.

· Skills gap: There is a shortage of cybersecurity professionals who understand both IT and OT protocols, resulting in insufficient risk management.

· Lack of awareness

· Other operational priorities

Comprehensive strategies for managing IT-OT cyber risks

Asset Visibility and Inventory

A foundational step in managing cyber risks is establishing full visibility into all devices, networks, and endpoints across IT and OT environments.

· Conduct periodic asset discovery scans.

· Classify devices by type, manufacturer, protocol, and criticality.

· Maintain a real-time asset inventory integrated with security and incident management platforms.

· Use a OT security platform like Shieldworkz to get a clear view of your assets on an ongoing basis

What to do? Use network traffic analysis tools capable of identifying industrial protocols and obscure endpoints. Get in touch with our OT asset management expert. 

Network segmentation and zoning

Segmentation reduces lateral movement within the network and confines potential attacks.

· Create separate zones for IT and OT networks using firewalls and VLANs.

· Implement demilitarized zones (DMZs) for controlled data exchange.

· Limit cross-zone communication based on necessity and security posture.

What to do? Use deep packet inspection and strict access policies tailored to protocol-specific traffic.

Identity and Access Management (IAM)

Strong authentication protocols are critical for preventing unauthorized access.

· Implement multi-factor authentication (MFA) across both IT and OT interfaces.

· Enforce role-based access control (RBAC) and least-privilege principles.

· Monitor and review access logs regularly.

What to do? Integrate IAM solutions with OT network monitoring tools to detect anomalies such as unusual access patterns.

Patch and update management

Patch management in OT is challenging due to operational constraints but essential for reducing known vulnerabilities.

· Identify critical patches and schedule downtime windows for updates.

· Apply virtual patching when immediate patching is not possible.

· Work with vendors for firmware upgrades and support lifecycles.

· Track and close attack paths

Best Practice: Automate vulnerability scans that correlate known exploits with deployed device firmware.

Threat detection and response

Real-time monitoring and incident response are vital in converged environments.

· Deploy intrusion detection systems (IDS) and industrial threat detection platforms.

· Use anomaly detection algorithms to spot deviations from normal operations.

· Establish incident response playbooks that include both IT and OT escalation protocols.

Best Practice: Integrate threat intelligence feeds that focus on industrial malware, ransomware, and advanced persistent threats (APTs).

Data protection and encryption

Data flowing between IT and OT systems must be secured against interception and tampering.

· Encrypt communications between network zones and remote devices.

· Implement secure tunneling protocols such as VPNs and TLS.

· Ensure sensitive operational data stored on edge devices is encrypted.

Best Practice: Use hardware-based encryption where possible to prevent performance degradation.

Employee training and awareness

Human error remains one of the most significant risks. Training programs must be tailored to both IT staff and OT operators.

· Conduct regular cybersecurity drills and phishing simulations.

· Educate staff on recognizing suspicious activity and reporting protocols.

· Foster a culture of accountability and security-first thinking.

Best Practice: Include OT-specific scenarios, such as misconfiguring control systems or inadvertently exposing equipment to unauthorized access.

Supply Chain Risk Management

Third-party vendors and contractors require robust oversight.

· Establish strict vendor assessment protocols and security requirements.

· Conduct audits and penetration testing for vendor-managed systems.

· Implement contractual obligations for timely patching, reporting, and incident response.

Recommendation: Use zero-trust principles when integrating vendor access with internal networks.

Compliance and governance

Adhering to regulatory frameworks builds trust and minimizes penalties.

· Map controls to relevant standards like IEC 62443, NIST, and ISO 27001.

· Document risk assessments, controls, and mitigation plans.

· Engage external auditors for third-party validation.

· Apply compensatory controls wherever possible

· Have a written policy in place for guiding governance and compliance

Best practice: Use governance, risk, and compliance (GRC) tools that integrate both IT and OT security reporting.

Future-proofing cyber risk management

As IT-OT convergence accelerates, organizations must evolve their security posture continuously:

· Adopt AI and Machine Learning: Use AI-driven analytics to detect subtle threats that traditional signature-based tools may miss.

· Leverage Edge Security: Implement security measures closer to devices, especially in distributed or remote environments.

· Build Cross-Functional Teams: Integrate IT, OT, engineering, and compliance teams under a unified security strategy.

· Plan for Resilience, Not Just Prevention: Establish redundancy, disaster recovery protocols, and fail-safe mechanisms to ensure continuity during attacks.

The convergence of IT and OT systems offers tremendous opportunities to improve operational efficiency, reduce downtime, and enhance decision-making. However, this integration also exposes industries to complex cyber risks that cannot be addressed with traditional security approaches alone. By implementing a comprehensive strategy, including asset visibility, network segmentation, access controls, threat detection, encryption, and compliance governance, organizations can mitigate risks and safeguard critical infrastructure.

Managing cyber risks in an IT-OT converged environment is not a one-time project but an ongoing process that demands cross-disciplinary collaboration, real-time intelligence, and a culture of resilience. By proactively addressing vulnerabilities and aligning security practices with industry standards, enterprises can harness the full potential of digital transformation while protecting their most critical assets.

Get in touch with us for a custom convergence risk management package for your business.