OT and IT convergence challenge for a manufacturing major

A large manufacturing company faced critical security challenges due to distributed OT networks and complex, compliance-driven connectivity needs. The organization aimed to secure OT systems at their main plant and gradually extend protection across other global sites.

Challenges

Key pain points identified:

No visibility into distributed OT environments
Limited understanding of OT-specific vulnerabilities
No actionable insights during cyberattacks
Multiple IT-OT connections, including third-party links

The Solution

Pragya conducted detailed site visits and audits to understand the client’s OT infrastructure and the broader cyber threat landscape. Packet captures from OT systems were analyzed to detect threats and identify areas lacking basic security hygiene.

Our key recommendations included:

Deploying endpoint security on plant workstations
Restricting USB access across OT environments
Integrating anomaly detection software with ruggedized firewalls

These measures significantly improved visibility and threat detection across both physical IT and OT assets.

Outcomes

The engagement resulted in:

A complete Bill of Materials (BoM) for solution implementation
A clear scope of work for phased security rollout
Improved asset visibility and OT threat response planning

The organization now had a structured path to secure its OT environments and strengthen IT-OT convergence.

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