Top 7 OT security use cases every industrial enterprise must implement

In the era of Industrial IoT (IIoT) and IT/OT convergence, the security of Operational Technology (OT) is now a business-critical imperative. A cyberattack on a Programmable Logic Controller (PLC) or a SCADA system can lead to physical damage, environmental disasters, and catastrophic operational downtime. Unlike what is being spoken about in the media and elsewhere, attacks on OT systems and infrastructure are preventable. This is not about how many billions an attack might cost but instead about practical and easy to implement OT security measures that can prevent a factory or sub-station shutdown.

Further, to protect your manufacturing, energy, utilities, or transportation systems, implementing robust OT security use cases is essential. In today’s blog post, I outline the top 7 use cases that every industrial enterprise must adopt to build a resilient and secure operational environment that is disruption proof and secure at every level.

Don’t forget to check out our previous blog on “a comprehensive and actionable guide to IEC 62443-based OT security assessments” here. This post does a deep dive into the various strategies and methods you can adopt to better align your OT security assessment with the IEC 62443 family of standards. 

Use case one: Comprehensive OT asset inventory and visibility

Summary: Operating as an OT asset aware organization. 

You cannot protect what you don't know or are aware of. This is a foundational use case for any OT security program that is oriented towards achieving complete, real-time visibility into every device on the network.

• What does it cover: A detailed and continuously updated list of all OT assets, including Industrial Control Systems (ICS), PLCs, Human-Machine Interfaces (HMIs), sensors, and gateways. This inventory must document the device type, manufacturer, model, firmware version, location, communication protocols, authorized behaviors and patch status. OT security solutions such as Shieldworkz can also help in asset discovery and management

• Why is it critical: Many OT devices are decades-old legacy systems that simply cannot be patched. Asset inventory tools (allowing passive, non-disruptive monitoring such as Shieldworkz) automatically discover these devices, revealing the true attack surface and helping to identify unauthorized devices or shadow assets. This level of visibility and asset awareness is the starting point for risk assessment and network segmentation.

Use case two: Robust and unbreakable network segmentation and true Zero Trust

Summary: Operating with unbreachable barriers, privilege by trust and higher levels of resilience

Network segmentation is the most effective way to limit the lateral movement of an attacker or the spread of malware from the IT network into the critical OT environment. It serves to contain vector movement and ensures faster recovery of systems in the event of a cyberattack or a breach. It also serves to contain the activity of a rogue insider.

• What does it cover: Physically or logically dividing the OT network into smaller, isolated zones (like for instance between the corporate IT network, the DMZ, and various control zones like SCADA, historians, and safety systems). This is often enhanced by Micro-segmentation, which isolates critical assets (like individual PLCs) or functional groups. The IEC 62443 standards can serve as a guide for the segmentation of networks.

• Why is it critical: If one segment is compromised (a malware infection on an engineer's workstation or someone plugging in an infected USB media into a workstation), the segmentation prevents the cascading failure from reaching mission-critical control devices. Implementing a Zero Trust model in OT mandates that no user or device is trusted by default, regardless of its location, requiring strict authentication and authorization for all traffic.

Use case three: Secure Remote Access and access control (IAM/PAM)

Summary: Operating with additional security layers to prevent attacks from breaching core systems from remote installations. 

The need for remote diagnostics, maintenance, and support for geographically dispersed industrial sites introduces significant risk. Controlling and auditing this access is paramount.

• What does it cover: Using secure technologies like Multi-Factor Authentication (MFA) and secure Jump Servers or encrypted VPNs to manage external access. This is paired with Privileged Access Management (PAM) and Role-Based Access Control (RBAC) to ensure that industrial engineers, integrators, and third-party vendors only get the minimum access necessary (Principle of Least Privilege) for their specific task.

• Why is it critical: Unsecured remote access is a primary threat vector for ransomware attacks (like the Colonial Pipeline incident). Secure remote access ensures that external connections are monitored, logged, and automatically revoked when the session ends, significantly reducing the risk of unauthorized command execution or data exfiltration.

Use case four: Continuous anomaly and threat detection

Summary: Operating as a threat and risk-aware organization on an ongoing basis.

OT networks typically have highly predictable traffic patterns. Any deviation from this normal "baseline" is an indication of a potential threat.

• What does it cover: Deploying specialized OT-aware Intrusion Detection Systems (IDS) such as Shieldworkz that understand industrial protocols (like Modbus, DNP3, and OPC) to continuously monitor network traffic. These systems establish a baseline of normal behavior and use analytics or AI to flag any anomalous activity that deviates from it.

• Why is it critical: This use case enables the early detection of threats that traditional IT tools miss, such as:

  • Unusual PLC Reprogramming: An unauthorized logic change to a controller.

  • Abnormal Command Sequences: A SCADA command that is out of order or outside safe parameters.

  • Scanning Activity: An attacker probing the OT network for vulnerabilities.

  • Malicious Insider Activity: A trusted user performing unauthorized actions.

Use case five: Vulnerability and patch management

While patching OT systems can be operationally disruptive, managing vulnerabilities, especially for legacy equipment is a critical security use case.

• What does it cover: Proactively identifying vulnerabilities (e.g., outdated software, weak configurations) on OT assets and developing a strategy to mitigate the risk. Since many OT devices cannot be patched without system downtime, this often involves Compensating Controls (like virtual patching via an IDS/IPS or network micro-segmentation) to reduce the vulnerability exposure.

• Why is it critical: The CISA Known Exploited Vulnerabilities (KEV) Catalog shows that unpatched systems are a frequent target. This process is about risk prioritization, focusing on remediating the highest-risk vulnerabilities first, either through patching or implementing alternative defenses that allow the critical system to remain operational.

Use case six: Incident Response and disaster recovery planning

Summary: Getting back on your feet faster during a cyber crisis

A cyberattack on an industrial environment requires a response plan distinct from a standard IT breach, prioritizing physical safety and restoration of operations.

• What does it cover: Developing and regularly testing a comprehensive OT-specific Incident Response Plan. This plan outlines clear roles and procedures for detection, containment (e.g., isolating a compromised segment), and recovery (e.g., restoring validated backups). It also mandates frequent and secure, offline backups of critical PLC/DCS configurations and operational data.

• Why is it critical: In an OT incident (like a ransomware attack or physical process disruption), quick, coordinated action is essential to maintain safety and minimize production loss. Simulating attack scenarios (tabletop exercises) ensures that IT, OT, and safety personnel can execute the plan efficiently, dramatically reducing the Mean Time to Recovery (MTTR).

Use case seven: Supply chain and third-party risk management

Summary: Reducing risks emerging from third-parties

The modern industrial environment is reliant on a complex web of vendors, integrators, and software suppliers, each introducing potential vulnerabilities.

• What does it cover: Establishing a formal program to vet the security posture of third-party vendors and their products. This includes implementing security requirements in contracts, securing the remote access they use (see Use Case 3), and closely monitoring the data and code introduced via the supply chain(e.g., new software updates, device firmware).

• Why is it critical: Supply chain attacks, where an attacker compromises a vendor to gain access to a target’s network, are an increasingly common threat. By securing the external entry points and validating vendor security controls, you can protect your ICS environment from risks originating outside your immediate control.

Implementing these top 7 OT security use cases moves your enterprise beyond checklist-based reactive compliance and toward true operational resilience. By prioritizing visibility, segmentation, access control, and proactive monitoring, industrial enterprises can safeguard their physical processes, protect public safety, and ensure uninterrupted production. Don't wait for a breach or crisis; the time to secure your industrial control systems is now.

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