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Johnny Xmas, the global head of offensive security for a major U.S. manufacturer, emphasized the growing importance of offensive security practices within operational technology (OT) environments in the manufacturing sector. In a detailed interview ahead of the 10th ManuSec Summit, he highlighted the unique challenges that manufacturing organizations face when implementing red teaming and penetration testing in OT settings. One of the primary hurdles is the inconsistent technology landscape across multiple manufacturing plants, which complicates the standardization of security assessments. Shadow IT, or unauthorized technology deployments, introduces hidden risks that can undermine even well-designed security programs. Xmas stressed the necessity of thorough asset inventory verification from an attacker's perspective, ensuring that all devices and systems present in manufacturing plants are accounted for and authorized. He pointed out that in OT environments, understanding the context of systems and processes is often more critical than focusing solely on technical exploits. Manufacturing organizations frequently encounter two major blind spots: incomplete visibility into their OT assets and a lack of understanding of how those assets interact within the broader operational context. These gaps can leave critical systems exposed to sophisticated attacks. Xmas also discussed the evolving role of security in OT, noting that it is increasingly becoming a core consideration for manufacturing leadership, rather than an afterthought. He advocated for a holistic approach to offensive security, integrating both IT and OT perspectives to maximize operational resilience. The interview underscored the need for specialized skills and methodologies tailored to the unique requirements of OT environments, as traditional IT security approaches may not be directly applicable. Xmas's insights reflect a broader industry trend toward proactive security measures, such as red teaming, to identify and remediate vulnerabilities before they can be exploited by adversaries. He also touched on the future of OT security, predicting that as manufacturing systems become more interconnected, the demand for advanced offensive security capabilities will continue to grow. The discussion provided actionable guidance for manufacturing CISOs, including the importance of cross-functional collaboration and continuous improvement in security practices. By prioritizing offensive security, manufacturers can better defend against emerging threats and ensure the integrity and availability of their critical operations. The interview serves as a call to action for manufacturing organizations to invest in robust red teaming and pentesting programs tailored to the complexities of OT environments. Ultimately, the integration of offensive security into manufacturing operations is positioned as a strategic imperative for safeguarding industrial assets and maintaining competitive advantage in an increasingly digital landscape.
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Ed Harris, the global director of information security at Mauser Packaging, has emphasized the growing importance of securing operational technology (OT) environments in the manufacturing sector. As manufacturing systems become increasingly connected, the risk profile for OT has expanded, making it a more attractive target for cyber attackers. Harris highlighted that OT security, once a theoretical concern, is now a practical necessity as threat actors actively seek vulnerabilities in these environments. He stressed the need for IT security executives to develop a deep understanding of OT-specific risks, which differ significantly from traditional IT threats. The integration of IT and OT systems introduces new connectivity and security challenges, requiring a careful balance to avoid disrupting essential manufacturing operations. Harris advocates for close collaboration between IT security teams and engineering departments to leverage specialized knowledge and build robust cybersecurity defenses. He pointed out that engineering teams possess critical insights into the operational aspects of OT systems, which are vital for designing effective security controls. The interview also addressed the importance of maintaining operational efficiency while implementing security measures, as excessive restrictions can hinder production processes. Harris’s experience, spanning over 30 years in cybersecurity across various manufacturing companies, informs his approach to managing these complex environments. He noted that the historical separation between IT and OT is no longer viable, and organizations must adopt integrated strategies to protect both domains. The discussion took place in the context of the upcoming ManuSec Summit in Chicago, where over 150 IT and OT security leaders are expected to convene and share best practices. Harris’s insights underscore the urgency for manufacturing organizations to reassess their security postures in light of evolving threats. He also mentioned the need for ongoing education and awareness among both IT and OT personnel to keep pace with the changing threat landscape. The conversation highlighted that regulatory pressures and industry standards are increasingly mandating stronger OT security controls. Harris concluded by encouraging organizations to proactively address OT security challenges before they result in significant operational disruptions. The interview serves as a call to action for manufacturing leaders to prioritize OT security as a core component of their overall risk management strategy. By fostering partnerships between IT and engineering, companies can better safeguard their operations against emerging cyber threats.
Jun 29, 2026
Industrial and manufacturing organizations continue to face significant **operational technology (OT)** security risk as connected control systems, IoT devices, and legacy infrastructure expand the attack surface. A Siemens Energy report cited by *TechRepublic*, based on Ponemon Institute survey data, found that **77%** of respondents said an OT security compromise in the past 12 months led to loss of confidential information or operational disruption, while **52%** said a successful exploit against their industrial control systems is likely within the next year. Respondents also estimated that **41%** of OT attacks go undetected, with many organizations taking more than a month to detect incidents and an average of seven months to recover. The broader picture is that smart factories are still struggling with basic cyber resilience as modernization outpaces security controls. In an interview with *Help Net Security*, Packsize CSO Troy Rydman said unmanaged **IoT** devices, outdated legacy systems, and human-targeted attacks such as phishing and social engineering remain major weaknesses in factory environments. He also highlighted the persistent tradeoff between production uptime and security requirements, underscoring that industrial operators are still balancing business continuity with the need to reduce exposure across connected devices and older operational systems.
Jun 29, 2026
Operational technology (OT) environments, such as manufacturing lines, refineries, pipelines, and rail control systems, are increasingly adopting advanced cyber defense strategies to address the unique challenges posed by modern cyber threats. Traditional perimeter-focused security models are being replaced by breach-ready cyber defense approaches that assume compromise is inevitable and prioritize rapid containment and resilience. This shift is driven by the recognition that OT systems often involve long-lived equipment, complex dependencies, and components that cannot be easily patched, making them particularly vulnerable to sophisticated attacks. At the CS4CA Europe conference, industry experts highlighted the growing need for virtual segmentation in OT environments as a practical means to implement zero trust principles and contain threats before they can propagate. Virtual segmentation allows organizations to enforce security boundaries within heterogeneous OT networks, even when physical segmentation is impractical or impossible. The approach emphasizes mapping attack paths, reducing the attack surface, and controlling lateral movement to prevent breaches from escalating. Regulatory bodies like CISA have updated their guidance to encourage dynamic, risk-based segmentation strategies tailored to the operational realities of OT. In these environments, safety and operational continuity are paramount, often taking precedence over traditional IT priorities such as data integrity and comprehensive patching. As OT systems increasingly connect to the cloud and integrate artificial intelligence, the attack surface expands, necessitating more agile and resilient defense mechanisms. Breach-ready strategies also include rapid response measures such as quarantining affected zones, isolating unaffected systems, and ensuring robust recovery and failover capabilities. The ultimate goal is to prevent cyber incidents from resulting in catastrophic outcomes, such as loss of life, environmental disasters, or disruption of critical national infrastructure. Industry practitioners are urged to assess their breach readiness, identify hidden lateral attack risks, and develop visual roadmaps for remediation. The convergence of IT and OT security teams is seen as essential for operationalizing zero trust and maintaining production while managing cyber risk. These evolving practices underscore the critical importance of proactive, layered defenses in safeguarding the foundational systems that underpin modern society.
Jun 29, 2026