OT Cybersecurity: Why Attacks Keep Rising — and What You Can Do Today to Protect Your Plant
- elliTek, Inc.
- 6 days ago
- 4 min read
Industrial manufacturers used to believe cybersecurity was “an IT problem.” Not anymore. Today, OT (Operational Technology) is the preferred target for cybercriminals because the stakes are higher: downtime, lost production, corrupted safety systems, IP theft, and even physical damage.
And attackers have figured out one thing: OT is often easier to infiltrate than IT.
At elliTek, we’re seeing the same pattern across East & Middle Tennessee: Manufacturers are modernizing production equipment, adding connectivity, expanding remote access — and unknowingly expanding their threat surface.
The good news?
You can take practical steps today to lock down your plant without slowing down operations. In fact, the right OT-focused security strategy actually strengthens uptime and reliability.
This article breaks down:
Why OT attacks are spiking
How attackers are getting in
The three biggest mistakes manufacturers make
Proven, real-world solutions: Siemens SCALANCE + TIA Security, WAGO Secure Linux & VPN, and Pilz SecurityBridge
What your team should do this quarter to harden your operation
Let’s get into it.
OT Cybersecurity: Why OT Cyber Attacks Are Increasing — Fast
Cybersecurity Ventures estimates that cybercrime will cost the world $10.5 trillion in 2025, and OT systems are now a top-tier target.
Why?
1. Legacy equipment was never designed for security.
PLC platforms from the 1990s and early 2000s assumed “security through isolation.” Today, those same controllers are connected to SCADA, MES, ERP, cloud analytics, and remote support tools.
2. Remote access exploded after COVID.
And with it, unsecured VPNs, unmanaged jump boxes, and shared vendor credentials.
3. OT networks lack segmentation.
Once an attacker gains a foothold, they can move laterally — quickly.
4. Safety systems and drives are now Ethernet-connected.
That means a misconfigured firewall or compromised laptop can reach the same network your safety PLCs sit on.
Manufacturers are feeling the pressure to modernize. Attackers are feeling the opportunity.
How OT Networks Are Being Breached Today
Here’s what elliTek sees most often during plant walk-throughs:
✔ Outdated switches and unmanaged Ethernet infrastructure
Flat Layer 2 networks with no VLANs or access control.
✔ Legacy PLCs with default usernames, no password, or open ports
Many OEM machines still ship this way.
✔ Remote access tools installed by vendors without IT/OT approval
TeamViewer, AnyDesk, or unsecured VPN tunnels.
✔ “Trusted” laptops connecting everywhere
Engineering laptops are the # 1 infection vector.
✔ Safety systems and motion drives on the same subnet as office PCs
This one is shockingly common.
If any of this sounds familiar, you’re not alone — and you’re not stuck.
Three Mistakes Manufacturers Make with OT Cybersecurity
1. Assuming IT security tools protect the plant floor
Endpoint protection and corporate firewalls stop threats at the enterprise level — not in Level 1/Level 0, where machines live.
2. Treating OT security as a one-time project
Cybersecurity is a lifecycle, not a checkbox.
3. Relying on “air gaps” that no longer exist
USB drives, Wi-Fi, vendor laptops, and cloud-enabled HMIs quietly eliminate air gaps every day.
You need hardened, industrial-grade tools specifically built for OT.
Best-in-Class OT Security Solutions That elliTek Represents
These are proven, field-tested solutions our team helps manufacturers deploy across Tennessee. They protect industrial networks without complicating engineering workflows.
1. Siemens SCALANCE + TIA Portal Security
Siemens’ OT-focused security stack combines industrial firewalls, segmentation, certificate-based communication, and controller hardening—all built into the automation ecosystem.
Why manufacturers rely on SCALANCE + TIA Security:
Industrial firewalls (SCALANCE S) are purpose-built for harsh environments
Defense-in-depth is implemented directly inside TIA Portal
Access control lists (ACLs) that lock down communication pathways
Security Level configurations for Siemens S7-1200, S7-1500, and Unified HMIs
Encrypted communication (TLS) between controllers and devices
User management & audit trails integrated into the PLC project
Simply put: You get machine-level security baked into your automation, not bolted on.
2. WAGO VPN Tunnels + Secure Industrial Linux
WAGO’s secure architecture is a great fit for OEMs, machine builders, and end users needing controlled remote access, resilient cyber protection, and industrial Linux hardened by design.
WAGO brings:
VPN-based encrypted tunnels for safe remote diagnostics
Port forwarding control to limit vendor access
Secure Linux OS with read-only file systems — nearly immune to ransomware
Firewall, NAT, and routing inside a compact industrial controller
Isolation between machine networks and corporate networks
Multi-user role management for traceable access
This is remote access done right — secure, audited, and OT-friendly.
3. Pilz SecurityBridge
Pilz is known for safety, but their SecurityBridge line delivers something priceless: Protection for safety systems and machine logic without interfering with your PLC code.
Perfect for guarding:
PNOZmulti
PESN / safety I/O
F-PLCs on safety networks
Benefits:
Blocks unauthorized access—even if credentials are compromised
Makes program modifications traceable
Provides a “one-way shield” around your safety logic
Doesn’t require changes to your existing safety program
Easy to deploy for OEMs or end users
SecurityBridge is the missing layer between cybersecurity and machine safety.
What You Should Do This Quarter to Protect Your OT Environment
Here’s an actionable, achievable roadmap:
1. Identify your OT assets.
If you don’t know what’s connected, you can’t protect it.
2. Segment your plant floor network.
Use VLANs and industrial firewalls (SCALANCE) to isolate cells.
3. Lock down remote access.
Move vendors to WAGO VPN or a managed access platform. Remove “ad hoc” tools.
4. Apply TIA Portal Security settings on all new and existing Siemens PLC projects.
Password protection isn’t enough — enable certificate-based access, know-how protection, and security levels.
5. Protect your safety systems.
Deploy Pilz SecurityBridge for PNOZmulti and safety PLC logic.
6. Train your engineering team.
Human error causes more breaches than malware.
7. Bring in experts early.
elliTek’s engineering team helps Tennessee & Virginia manufacturers assess, design, and implement OT security strategies that pair cybersecurity with real-world production efficiency.
Cybersecurity Is Now a Production Strategy—Not an Afterthought
In modern manufacturing, uptime is everything. A single compromised laptop can halt a line, shut down a plant, or corrupt your safety program.
The right OT-focused security architecture prevents that.
Whether you need:
SCALANCE firewalls and TIA security hardening
WAGO secure Linux/VPN remote access
Pilz SecurityBridge to lock down your safety systems
elliTek is here to help you strengthen your operation — without slowing it down.
Ready to take the next step?
Reach out to elliTek or your local Field Sales Engineer to schedule an OT Cybersecurity Review and get actionable recommendations tailored to your plant.
Your production. Your people. Your peace of mind.
Let's secure it — beyond automation.