For years, operational technology (OT) systems like manufacturing plants and energy grids lived in isolation. The air gap kept them physically separate from corporate IT networks and a vital layer of security came with that separation. Today, as supply chains undergo rapid digital transformation and companies connect OT systems to IT networks to streamline efficiency, that barrier is gone, and with it, the integrity of the operational data driving every critical supply chain decision.
On the surface, the shift unlocks unprecedented opportunities: real-time machine performance flows into enterprise resource planning (ERP) platforms, sensor data feeds predictive analytics dashboards, and production metrics integrate with demand planning systems. But the tradeoff is steep. The operational data executives rely on for inventory optimization, demand forecasting, and logistics planning are now exposed to the same attack vectors that breach IT networks. A single phishing email in the front office can cascade into a factory floor, corrupting systems and the data streams that power AI-driven supply chain insights, predictive maintenance algorithms, and automated decision-making.
The hidden cost of OT breaches
While the average cost of an industrial breach now exceeds $5.56 million per incident, an 18% increase over the prior year, there is a hidden cost that is even greater. Compromised operational data can poison supply chain analytics for months, leading to phantom demand signals, flawed capacity planning, and poor inventory decisions based on manipulated sensor readings.
The Colonial Pipeline attack underscored this reality. Though the ransomware never touched operational systems, executives shut down the pipeline to contain the attack and prevent it from spreading, demonstrating how quickly digital incidents can lead to real-world disruption.
Today’s supply chain leaders face a stark new reality. The operational data powering their digital transformation initiatives is only as secure as their most vulnerable OT endpoint, no matter how advanced the broader IT protections may be.
Closing the OT skills and visibility gap
Technology has moved faster than workforce readiness. In many organizations, IT teams are assigned OT security by default, often without the resources or specialized training to handle it. That creates a visibility gap in addition to a skills gap, with IT teams trying to secure systems they’ve never worked with and attackers working quickly to exploit blind spots.
As threat actors increasingly target OT infrastructure, with 73% of OT professionals reporting intrusions that impact these environments, organizations can no longer rely solely on traditional IT security practices. Resilience starts with defense, and without teams trained to recognize, contain, and respond to attacks, even the strongest security technologies can fail under pressure. By investing in cross-functional, OT-focused training, organizations can close the skills gap and ensure teams are prepared to protect both systems and the data that fuels supply chain performance.
From compliance to operational resilience
Regulatory frameworks such as NIS2, IEC 62443, NIST SP 800-82, and guidance from agencies like the NSA and CISA can provide valuable guardrails. However, legislation and frameworks are only paper shields if organizations aren’t ready to fight back. Resilience requires more than policies; it demands building visibility across OT assets, locking down access, and stress-testing incident response plans under real-world conditions.
Real progress comes when supply chain leaders treat OT security as the foundation of operational resilience, ensuring that systems and the data they generate can withstand disruption. This includes:
● Discovering assets and assessing risk: Hidden or legacy assets create blind spots in data pipelines. A proper inventory clarifies what needs protection, which data sources underpin critical supply chain analytics, and how data corruption could cascade through decision-making systems.
● Strengthening access controls and network segmentation: Flat networks make it easy for attackers to move laterally. Segmentation between IT and OT, combined with strict identity controls, limits damage and protects the integrity of data pipelines.
● Exercising incident response plans: Most plans remain IT-centric. OT requires scenarios that account for physical processes, safety, and time-sensitive coordination. Regularly exercising these plans ensures both system recovery and data continuity.
● Implementing OT-focused cybersecurity training: Upskilling employees builds the bridge between IT and OT teams, enabling them to respond together when attacks occur.
● Breaking down silos between IT and OT teams: Security is a team sport. Shared governance, joint threat exercises, and security champions across both domains help eliminate blind spots and improve response times.
The time is now
The air gap has disappeared, and the time to secure OT environments was the moment they were installed, not as an afterthought. Defense and analytics are inseparable in a world where operational data drives supply chain performance.
Organizations that invest in skilled people, resilient systems, and united IT/OT teams will not only minimize disruption but also gain an edge. Resilient supply chains are visible, reliable, and built on data that leaders can trust. The time to act is now.
