Here’s a hard truth: most manufacturers don’t really know everything that’s happening on their plant floor networks.
And that’s not because you’re careless—it’s because operational technology (OT) environments are complex. You’ve got old machines running alongside modern connected systems, vendor-installed equipment that wasn’t designed for cybersecurity, and IoT devices that seem to appear overnight.
According to the 2024 State of OT and Cybersecurity Report, only 5% of organizations have full visibility into their OT systems. That means 95% are running blind in some way.
For manufacturers, those blind spots can be costly.
In most factories, blind spots aren’t obvious. Things look like they’re running fine—until they aren’t. Here’s what we see most often:
Unmonitored devices: A contractor plugs in a laptop or a new piece of equipment connects without IT/OT approval.
Legacy systems: Old PLCs or SCADA systems that don’t support modern security tools.
Shadow connections: Employees use wireless devices or remote apps that never get documented.
Vendor access: Suppliers log in remotely to troubleshoot machines, but their access isn’t tracked or limited.
The problem? If you don’t see it, you can’t secure it. Attackers love these blind spots—they’re hidden doors into your production network.
Manufacturers face unique challenges that make blind spots almost inevitable:
Mix of old and new tech: Unlike office IT, you can’t just “upgrade” every plant system. Machines are built to last decades, not three-year refresh cycles.
Uptime pressure: Production can’t stop just to apply a security patch or replace outdated hardware.
Multiple vendors: Every machine or system might come from a different supplier with different standards.
Thin IT teams: Most manufacturers don’t have the luxury of a big in-house security staff.
The result? A patchwork environment where some systems are protected, and others are flying under the radar.
Blind spots in OT security aren’t just technical problems—they hit directly at the heart of your business:
Downtime you didn’t see coming: An undetected vulnerability gets exploited, halting production.
Compliance failures: Regulators expect you to know what’s connected and how it’s secured.
Supply chain risk: If your plant is compromised, your customers may see you as the weak link.
Safety hazards: A tampered machine setting can put workers at risk.
Even if your IT systems are locked down, OT blind spots can undo all that hard work.
The good news: closing these gaps doesn’t require reinventing your plant floor. Here are some practical steps:
Start with asset inventory. You can’t secure what you don’t know exists. Document every device, old and new.
Segment your networks. Separate IT from OT, and further separate OT systems from each other. That way, one blind spot doesn’t compromise everything.
Use OT-aware monitoring tools. Generic IT monitoring won’t catch everything on the plant floor. You need tools that understand industrial protocols and devices.
Control vendor access. Make sure remote support sessions are secure, logged, and limited.
Train your people. Employees on the floor often notice unusual behavior first—make them part of your defense.
At TotalCare IT, we’ve worked with manufacturers across Idaho who faced the exact challenges above. Our team helps plants:
Uncover hidden devices and connections
Deploy monitoring that works for both IT and OT
Build secure segmentation between plant systems
Manage vendor access without slowing down production
Provide leadership with real-time visibility and reporting
The bottom line: when you can see everything on your network, you can protect it. And that means fewer surprises, less downtime, and more confidence in your operations.
You wouldn’t ignore a warning light on a production machine—so don’t ignore the hidden gaps in your OT network.
Schedule a quick 15-minute call with TotalCare IT. We’ll help you find and fix the blind spots in your OT security before attackers do.