Manufacturer Secures OT/IT Environment
The Challenge
The manufacturer operates three plants producing critical components for automotive and aerospace customers. When a competitor was shut down for two weeks by a ransomware attack, their customers demanded immediate security improvements.
The challenge was complex: 15-year-old PLCs and SCADA systems couldn't be patched or replaced without $10M+ investment. These legacy systems were directly connected to the corporate network-IT could ping production equipment from their desks.
Any security project had to guarantee zero production impact. A single hour of unplanned downtime cost $150K in direct costs plus potential customer penalties for missed shipments.
Our Approach
OT Asset Discovery & Risk Assessment
Week 1-4Performed passive network discovery to map all OT assets without disruption. Identified 340+ devices including 45 with critical vulnerabilities.
Network Segmentation Design
Week 4-8Designed Purdue Model-based segmentation with DMZ between IT and OT. Created traffic flow requirements with plant engineers.
Phased Implementation
Week 8-20Deployed industrial firewalls and segmentation during planned maintenance windows. Implemented over 6 weeks with zero production impact.
Monitoring & Vendor Access
Week 20-26Deployed OT-aware monitoring, implemented secure remote access for equipment vendors, and created incident response runbooks.
Solution Overview
OT/IT network segmentation, industrial firewall deployment, secure remote access for vendors, vulnerability management, and incident response planning.
The Results
Business Impact
"PlatOps understood our unique challenges. They secured our systems without impacting production."
PPlant Manager, industrial equipment manufacturerIndustrial Equipment Manufacturer
"Our biggest customer said our security posture now exceeds many larger suppliers. That's a competitive advantage."
VVP of Operations, industrial equipment manufacturerIndustrial Equipment Manufacturer
Key Takeaways
- OT security must prioritize availability over confidentiality
- Passive discovery is essential-active scans can crash legacy systems
- Vendor remote access is often the biggest security gap
- Customer security requirements are driving manufacturing security investment
Key Outcome
Technologies Used
Compliance Frameworks
Want Similar Results?
Let's discuss how we can help your organization achieve its goals.
Book a free 1-hour callServices in This Project
Industry Solutions
More Manufacturing Success Stories
Ready to Write Your Success Story?
Join the organizations that have transformed their security and infrastructure with PlatOps.