Long-Form Guide
Digital systems now connect every part of industrial operations, from traditional IT networks to operational technology (OT) and industrial control systems (ICS). This integration creates security challenges that legacy access controls were not designed to handle.
Manufacturing plants, utilities, and other critical infrastructure operators are now exposed to increased cyber risk as interconnectivity expands across teams, vendors, and remote workflows.
Gartner's 2023 Market Guide for Operational Technology Security projects that by 2027 most security teams will use at least five CPS security tools in mission-critical environments.
Physical operations need different protection
OT and ICS systems directly control physical equipment and industrial processes, so they carry different risk and reliability requirements than enterprise IT.
Key differences include:
- Legacy protocols without native security features (Modbus, DNP3, BACnet).
- Outdated operating systems that often cannot be patched on normal cycles.
- Operational changes that require extensive testing to avoid process disruption.
- Equipment life cycles of 15 to 20 years versus 3 to 5 years in IT.
- Downtime that impacts safety, reliability, and production commitments.
- Real-time system constraints that limit available security controls.
Recent reporting shows 54% of US critical infrastructure suppliers experienced attempts to control systems, and 40% faced shutdown attempts. Average OT incident impact is often measured in millions.
Remote user access amplifies risk
Remote operations now require third-party vendors, employees, and contractors to access critical systems from distributed locations. Traditional remote access models create blind spots in this operating model.
Common challenges include:
- Remote workers connecting from unmanaged or partially managed endpoints.
- Vendors requiring privileged access for maintenance and emergency support.
- VPN access models that overexpose networks beyond least privilege.
- Jump hosts that add complexity and create new attack surface.
- Limited visibility into user behavior and high-risk activity.
- File transfer workflows that bypass standard controls.
- Credential sharing across vendor teams and contractors.
ICS-CERT investigations in critical manufacturing have risen sharply, with remote access repeatedly identified as a primary initial access vector.
Compliance gets more complex
Industrial organizations now operate under overlapping cybersecurity obligations across sectors and geographies. Security teams must map controls across IT and OT while maintaining operational continuity.
Frameworks teams frequently align to
- NERC CIP requirements for bulk electric system operators.
- ISA/IEC 62443 controls for industrial automation and control systems.
- TSA directives for pipeline and transportation environments.
- FDA 21 CFR Part 11 controls for regulated manufacturing records.
- DOE and other critical infrastructure cybersecurity guidance.
Evidence expectations that drive workload
- Detailed access documentation and least-privilege enforcement proof.
- Real-time monitoring, alerting, and anomaly escalation records.
- Periodic access review and recertification workflows.
- File transfer approval and integrity evidence.
- Comprehensive immutable audit trails.
- Multi-factor authentication records and policy evidence.
- Separation-of-duties enforcement across IT and OT roles.
- Change management logs tied to access and policy updates.
Security teams lack cross-domain OT training
IT-OT convergence has exposed a practical skills gap: many practitioners are strong in IT or OT, but not both. This creates design, deployment, and incident response friction.
The gap often appears as:
- IT teams unfamiliar with industrial protocols and safety constraints.
- OT teams prioritizing availability where security controls are still required.
- Limited expertise in protecting legacy and unsupported systems.
- Fragmented visibility due to disconnected tooling and ownership models.
- Difficult cross-team response coordination during security events.
- Insufficient documentation and repeatable training paths.
- Security changes that unintentionally disrupt industrial processes.
Ponemon Institute research found that 63% of organizations report insufficient staff with the IT-OT security skills needed to secure converged environments.
A unified approach to secure user access
Gartner's 2024 CISO Leadership findings elevated User Access, IAM, and Zero Trust to the top functional priority for CISOs.
Hyperport addresses these challenges by combining zero trust network access (ZTNA), privileged access management (PAM), and secure remote access (SRA) in one platform.
- Granular access controls across IT and OT systems.
- Support for industrial protocols and legacy operational constraints.
- Secure third-party and contractor access workflows.
- Comprehensive audit trails with real-time activity monitoring.
- Protected file transfer and policy-based governance controls.
- Integration into existing security and compliance workflows.
Instead of layering point products, organizations can use a unified secure user access platform to close security gaps while preserving operational uptime and safety requirements.