Top 5 security concerns for IT/OT integrations
As organizations accelerate IT/OT integration, they face new security risks tied to legacy systems, shared logins, and misaligned priorities. Here’s a checklist of top concerns to address when bringing IT and OT environments together.
Integrating IT and OT systems enables manufacturers to connect data, devices, and workflows, resulting in more efficient operations. Done right, it powers real-time decision-making, predictive maintenance, and smarter supply chains. But without proper security, IT/OT integration can introduce more risk than resilience.
Research shows why leaders are cautious:
- 46% of manufacturers cite security concerns as the top barrier to IT/OT convergence.
- 50% still rely on OT assets that are 15+ years old, which were not designed with modern security in mind.
- Only 30% can deliver real-time data to frontline workers — a critical gap for agile operations.
- Just 15% have mature cybersecurity practices.
The message is clear: IT/OT integration is inevitable, but it must be approached with a strong security foundation. Here are five concerns every organization should address.
1. Legacy infrastructure and outdated access
Most OT systems weren’t built with today’s security requirements. Shared logins are still common, creating accountability gaps and leaving no audit trail. Outdated access processes also slow teams down with frequent password resets and inconsistent workflows.
- Replace shared logins with badge + PIN or other individual authentication methods
- Extend secure workflows to both legacy and modern systems
- Minimize manual password resets with single sign-on (SSO)
2. Visibility of assets in IT/OT environments
You can’t protect what you can’t see. Legacy assets often lack consistent monitoring, making it difficult to detect vulnerabilities, unusual activity, or insider misuse. Access visibility is also crucial for supply chain security, particularly when third-party vendors interact with sensitive systems.
Checklist:
- Implement access visibility and activity logs across IT/OT environments
- Track “who accessed what, when, and where” to simplify audits and incident response
- Extend visibility to supply chain partners for stronger product security
3. Misaligned priorities between IT and OT
IT prioritizes security and data integrity, while OT teams focus on uptime and efficiency. Without collaboration, these competing risk appetites can hinder the integration of projects.
Checklist:
- Align IT, OT, and floor teams around shared security and productivity goals
- Introduce identity and access management (IAM) solutions that balance efficiency with compliance and security
- Use secure backup solutions to minimize downtime from cyber or operational disruptions
4. Workforce inefficiency and compliance gaps
Integration is more than a question of evolving technology. It’s a people challenge often exacerbated by a lack of expertise and skills. Training certification delays, inconsistent device access, and slow onboarding all erode productivity.
Checklist:
- Simplify logins across devices, shifts, and apps
- Use IAM to speed onboarding and reduce training friction
- Ensure compliance through consistent workflows and automated access policies
5. Emerging technologies and evolving threats
Cloud adoption, IIoT, and AI-powered automation expand the attack surface. Without least privilege policies and hardware that has gone through sometimes challenging security updates, attackers can exploit weak points at the edge of IT/OT systems.
Checklist:
- Enforce least privilege access across all IT/OT systems
- Harden devices with secure hardware and patch management as quickly and frequently as possible
- Continuously evaluate new threats as emerging technologies are deployed
IT/OT integration is essential for Industry 4.0 success, but it also comes with serious security concerns. Addressing outdated infrastructure, visibility gaps, siloed priorities, and emerging risks is non-negotiable.
With modern access management, organizations can reduce friction, strengthen accountability, and foster the trust necessary for effective IT and OT collaboration. The result is an environment where productivity and protection go hand in hand, unlocking the full potential of Industry 4.0.
Click here to learn more about how strategic access management can help your manufacturing floor optimize for both security and efficiency.