Operational Technology (OT) environments are vital to industries like manufacturing, energy, utilities, and transportation, to name but a few. Indeed most organisations have some degree of OT infrastructure in place. But as these systems become increasingly interconnected with IT networks, they’ve also become a growing target for cybercriminals. A single breach can bring production lines to a standstill, impact economies, compromise safety, and inflict long-lasting reputational and financial damage. 

In this blog we explore the six most common weaknesses in OT environments and how Integrity360 can help you overcome them. 

Lack of segmentation and flow management

One of the most widespread OT security gaps is poor network segmentation. In many environments, flat architectures mean there’s little to prevent a threat actor who breaches the IT network from moving laterally into OT systems. This is especially dangerous in converged environments, where the boundaries between business and operational domains are blurred. The Purdue Model and the IEC 62443 standard exist to address this by segmenting networks into defined layers (from enterprise systems down to field devices), but it’s often only partially implemented or poorly maintained. 

This lack of segmentation allows malware, ransomware, and unauthorised users to pivot between systems, exposing critical assets to exploitation. Once inside, attackers can disable safety systems, manipulate processes, or cause shutdowns with little standing in their way. 

How Integrity360 helps: 

Integrity360 addresses segmentation issues through targeted assessments such as IT/OT DMZ Penetration Testing and full Industrial Security 360 Audits. These engagements identify weak spots in interconnectivity, test how attackers might bypass segmentation, and provide actionable recommendations. Our OT Security Engineering service then helps design and implement segmentation using firewalls, network probes, and best-practice architecture aligned to IEC 62443. The result is stronger internal boundaries and reduced risk of lateral movement.

Unpatched systems and obsolete components

OT environments are notoriously difficult to patch. Unlike IT systems, where regular updates are expected, industrial devices often run for decades with minimal changes. Downtime is rarely acceptable, meaning updates are delayed or avoided entirely. As a result, many OT systems are left running outdated software versions or unsupported operating systems, riddled with known vulnerabilities. 

Attackers know this. Many ransomware variants specifically exploit unpatched systems or legacy industrial control systems (ICS). The presence of obsolete equipment also makes it harder to apply modern security tools, creating blind spots that attackers can exploit. 

How Integrity360 helps: 

Our OT Security Engineering team implements patch management solutions that are specifically adapted for OT environments. These tools identify applicable updates, help prioritise them based on criticality, and ensure changes can be safely scheduled to avoid operational disruption. During auditing, unpatched systems are flagged, and remediation roadmaps are created in line with regulatory expectations like NIS2 or ISO/IEC 27001. Additionally, we assist with legacy risk assessments, offering alternative protections such as network isolation, virtual patching, and compensating controls where upgrades are not feasible.

Lack of hardening

Many OT systems are deployed with minimal security configuration. Default passwords, open ports, inactive but enabled services, and poor access controls are common. These gaps result from a historic focus on uptime over cyber risk — but in today’s threat landscape, this mindset is increasingly dangerous. 

Attackers often exploit weakly configured systems as initial footholds. They look for exposed interfaces, legacy protocols like Telnet, or unencrypted communications. Once inside, they can escalate privileges, disable alarms, or spread malware across connected devices. 

How Integrity360 helps: 

We help our clients apply cyber hardening to OT systems through both consulting and engineering services. Our experts assess configurations, identify unnecessary services, and provide guidance on security baselines tailored for industrial systems. Technologies such as USB sanitisation stations, anti-malware software, PC control tools, and compliance monitoring are used to enforce secure configurations. We also help define OT-specific hardening policies that can be deployed at scale, aligning to standards like IEC 62443 and NIST SP800-82.

Unsecured remote access

Remote access is critical for many OT environments — from supporting remote engineers to enabling centralised monitoring. However, poorly secured remote access methods are among the most exploited vectors in modern industrial breaches. Examples include VPNs with default settings, unsecured remote desktop sessions, and shared credentials with minimal logging or control. 

These weaknesses are especially risky in scenarios where remote users have direct access to HMIs, PLCs, or SCADA systems. Without robust authentication, encryption, and logging, attackers can hijack these connections, manipulate systems in real-time, or deploy malware that disrupts operations. 

How Integrity360 helps:

 Our experts mitigate remote access risks by helping clients implement secure access solutions. This includes integrating administration bastions to act as gateways, enforcing MFA, and controlling user access by role and time. Our audits examine existing remote access paths and test for bypass techniques, while our engineering team designs architectures where remote access is routed through hardened environments with full logging and session monitoring. Furthermore, they advise on secure VPN configurations, certificate-based authentication, and integration of identity management systems for centralised control.

Lack of inventory and monitoring

You can’t protect what you can’t see. Many organisations have little or no visibility into their OT environments. Asset inventories may be out of date, fragmented across departments, or entirely absent. This lack of oversight makes it impossible to detect threats, respond effectively to incidents, or even identify high-risk systems. 

The issue extends beyond asset lists. Without monitoring tools that understand OT protocols and behaviours, unusual activities such as unauthorised communications, command injections, or configuration changes can go unnoticed until damage is done. 

How Integrity360 helps: 

Integrity360 provides visibility through their Engineering services, deploying network probes that automatically map OT environments. These tools detect asset types, firmware versions, communication paths, and behavioural baselines feeding into security dashboards that enable real-time monitoring. During audits, gaps in inventory are identified and documented. We also assist with building centralised asset repositories and integrating data into Security Information and Event Management (SIEM) systems. With these capabilities in place, organisations gain the situational awareness needed to detect intrusions and take timely action.

Unprotected assets against malware

Industrial systems often lack effective endpoint protection. Standard antivirus solutions are unsuitable for many OT environments due to compatibility issues, real-time constraints, and vendor restrictions. The result is that many critical assets are unprotected, leaving them vulnerable to ransomware and destructive malware. 

This exposure is particularly concerning given the rise of OT-specific threats like Industroyer, Triton, and the recent FrostyGoop malware that paralysed a heating utility in Ukraine. In some cases, the presence of a single infected laptop or USB device has brought entire operations to a halt. 

How Integrity360 helps: 

Integrity360 combats malware threats with a suite of solutions designed for OT compatibility. This includes deploying antivirus software that is validated for use in ICS environments, implementing USB scanning and sanitisation stations, and offering endpoint control solutions like PC Control to scan unmanaged workstations. Our Ransomware Dry Run service simulates attacks in a controlled way, testing endpoint defences, SOC detection, and response processes to help organisations prepare for the real thing. We also integrate malware protection into broader OT architectures, ensuring coverage without disrupting critical processes. 

Ready to secure your OT environment? 

Integrity360’s full suite of OT security services spanning Consulting, Engineering, Auditing, Investigations, and Training equips organisations with everything needed to protect, monitor, and defend industrial environments. Whether you need to comply with regulations like NIS2, perform a business impact analysis, or respond to a suspected breach, Integrity360’s specialists are ready to help. 

Most importantly, Integrity360 understands that in OT environments, availability and safety are paramount. Every engagement is tailored to minimise disruption while maximising long-term resilience. 

With cyberattacks growing in scale and complexity, now is the time to take OT security seriously. Integrity360 has the experience, expertise, and tools to help you assess your risk, close security gaps, and future-proof your operations. 

Visit integrity360.com to speak to one of our OT security specialists or request a consultation.