In 2023, over 75% of cyber incidents targeting critical infrastructure were traced back to unknown or unmanaged assets. Yet, most OT environments still operate without complete asset visibility. Unlike IT networks, where asset inventories are well-established, OT environments often rely on legacy systems, proprietary protocols, and air-gapped assumptions—leaving security teams blind to potential risks.

If you don’t know what’s connected to your network, how can you secure it?

A recent study by the Ponemon Institute found that 65% of industrial organisations lack real-time visibility into their OT assets, increasing the risk of cyber threats and operational disruptions. In one case, a global manufacturing firm suffered a $140 million loss when a single vulnerable PLC (Programmable Logic Controller) was exploited in a ransomware attack, bringing production to a halt for two weeks. These incidents illustrate why asset discovery is not just an operational necessity—it’s a security imperative.

The average time a hacker goes undetected in an Operational Technology (OT) environment can vary significantly. However, some reports suggest that the average “dwell time” for attackers in general environments can range from 11 days to 287 days.

(In OT environments, the detection time can be longer due to the specialised nature of these systems and the potential lack of advanced monitoring tools. This extended dwell time allows attackers to conduct extensive reconnaissance, move laterally within the network, and potentially cause significant damage before being detected.)

Why Asset Discovery is the Foundation of OT Security

Operational Technology (OT) networks underpin critical infrastructure—from energy grids to hospitals and manufacturing plants. However, these environments were not designed with modern cybersecurity threats in mind. The convergence of IT and OT has amplified the risks, making asset visibility the first line of defence against cyber threats.

 Key Challenges in OT Asset Management:

• Legacy Systems & Proprietary Protocols– Many OT devices were never designed to be monitored in real-time, making it difficult for traditional IT security tools to detect them. Many industrial systems still rely on Windows XP or older, unsupported firmware, making them prime targets for exploitation.
• Lack of Integration with IT Security Tools– OT environments often exist in silos, disconnected from broader security operations. Traditional IT-based asset management solutions struggle to interpret OT-specific communication protocols like Modbus, DNP3, and SCADA systems, leaving security teams with blind spots.
• Regulatory Mandates– Governments are ramping up pressure on critical infrastructure providers to improve security. The Australian Security of Critical Infrastructure (SOCI) Act requires organisations to maintain robust security postures, including asset visibility and risk assessments. Non-compliance can result in significant fines and legal implications, as seen in recent enforcement actions against non-compliant energy providers.

The Business & Security Risks of OT Blind Spots

Without complete asset discovery, organisations expose themselves to:

• Unpatched vulnerabilities in legacy systems– Attackers exploit outdated software that operators don’t even realise is running. In 2021, a water treatment facility in the U.S. was compromised when an attacker gained access through an unmonitored remote terminal, attempting to alter chemical levels in drinking water.
• Regulatory non-compliance– Failure to report asset risks can lead to penalties and reputational damage. In 2022, an Australian energy company faced scrutiny for failing to meet minimum cybersecurity standards outlined in the SOCI Act, resulting in operational disruptions and significant financial repercussions.
• Increased attack surface– Supply chain risks and ransomware attacks often originate from unmanaged devices. The infamous Norsk Hydro attack cost the aluminium producer an estimated $75 million in damages, largely due to attackers exploiting an unpatched OT device.

How to Approach Asset Discovery in OT

A robust OT security strategy starts with comprehensive, ongoing asset discovery. Here’s what IT and OT leaders should prioritise:

• Real-time Discovery & Risk Profiling– Understanding assets isn’t enough; organisations need current Critical Infrastructure Risk Management plans (CIRMP). Cyber threats evolve daily, and a one-time scan will quickly become outdated. Businesses must implement automated discovery tools that provide real-time insights into every device, protocol, and communication pathway within the OT environment.
• Compliance & Continuous Monitoring– Asset discovery should support ongoing compliance with frameworks like SOCI, NIST, and ISO/IEC 62443. This means maintaining detailed records of OT assets, tracking changes over time, and ensuring that vulnerabilities are addressed before they can be exploited.
• Integration with SOC & Threat Intelligence– Critical Asset require real time monitoring. The best security strategies feed asset data directly into Security Operations Centres (SOCs) and integrate with threat intelligence platforms. This approach enables organisations to proactively identify and neutralise threats before they escalate into full-scale incidents.

Beyond discovery, organisations need Compensating Controls or Positive Security Objects (PSO’s) to support operations across longer lifecycle assets. A know vulnerability can be addressed at with an effect Risk Management Plan, especially when primary controls are not feasible or effective. An example being OT Network segmentation to isolate high-risk devices and implementing Virtual Patching solutions tailored for OT environments.

 What Comes After Discovery?

Asset visibility is step one—but security leaders must also:

• Implement continuous monitoring and risk scoring to detect threats in real-time.
• Strengthen compliance reporting with actionable data for audits.
• Integrate asset discovery with OT SOC services for an end-to-end cybersecurity approach.

 The Future of OT Security: From Reactive to Proactive

OT security isn’t just about defending against threats—it’s about understanding your environment before an attacker does. Asset discovery isn’t a one-time project; it’s an ongoing strategy that lays the foundation for a resilient, compliant, and secure OT ecosystem.

The reality is, no security strategy is complete without full visibility into the assets within an OT network. As threats evolve and regulations tighten, organisations that fail to address asset visibility will find themselves increasingly vulnerable—not just to cyberattacks, but to regulatory penalties and operational failures.

Orro helps organisations navigate the complexities of OT security with real-time digital asset discovery, network segmentation and virtual patching, managed OT SOC services, and compliance-driven solutions. Our expertise ensures that organisations don’t just identify their assets—they protect them.

Want to know where your blind spots are? It’s time to find out.

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From AI-driven advancements to groundbreaking developments in security, networking, and operational technology (OT), Cisco’s unified approach—what I’d call the “One Cisco” strategy—brings together its full portfolio to deliver integrated solutions greater than the sum of their parts. Here’s a closer look at the key themes and insights that will shape the future of enterprise technology.

AI and Security: Powering the Next Generation of Digital Infrastructure

At the heart of Cisco’s innovation is its investment in AI and security. These aren’t standalone advancements; they’re deeply integrated into Cisco’s technology stack to drive real-world outcomes.

Unified AI Assistant

Cisco introduced a skills-based Unified AI Assistant, designed to handle everything from policy setting and configuration to detecting and responding to threats like ransomware. By leveraging AI’s capabilities, this tool simplifies complex processes, enabling businesses to operate with greater agility and security.

Splunk Integration

The recent acquisition of Splunk was another standout moment, signaling a leap forward in Cisco’s security and observability capabilities. By cross-correlating vast datasets, Splunk enables faster, more effective threat detection and resolution—an essential capability for organisations navigating today’s cyber threat landscape.

Hypershield Security

Cisco’s Hypershield technology represents a fundamental shift in network security. By embedding AI-native security directly into the network fabric, Cisco ensures that threats are mitigated at every level, aligning with the principles of zero-trust architecture. This distributed approach prevents lateral movement of threats, enhancing resilience across hybrid and edge environments.

Customer Experience: Personalised, Predictive, and Seamless

Cisco is redefining customer experience with innovations designed to make technology intuitive, integrated, and impactful. This goes beyond technical capabilities to consider the end-user’s journey, ensuring organisations can extract maximum value from their technology investments.

Cross-Architecture Integration

Central to this is Cisco’s commitment to cross-architecture integration and open ecosystems. By uniting networking, security, observability, and collaboration tools, Cisco creates seamless, interoperable solutions that adapt to an organisation’s unique requirements.

Workspace Transformation

Innovations like the Cisco Ceiling Microphone Pro and workspace designer tools are tailored for hybrid work environments, improving the experience of remote and in-office collaboration alike. These tools are part of Cisco’s broader strategy to eliminate the barriers of distance, creating what they call a “distance zero” work environment.

Proactive, Predictive AI

Cisco’s focus on personalised and predictive AI interactions elevates customer support and engagement. By integrating AI into tools like Cisco’s assistant, organisations can anticipate issues, optimise performance, and improve decision-making—enhancing both efficiency and satisfaction.

Operational Technology: Extending the Edge

As industries continue to converge IT and OT environments, Cisco is making significant strides to support operational technology (OT) applications. This is a pivotal area for Orro, and the insights from these events underline the growing importance of OT in enterprise strategies.

IoT and Edge Computing

Cisco’s edge computing solutions are designed to extend the power of the data centre to industrial and IoT applications. Whether in manufacturing, energy, or transportation, these technologies provide consistent security, performance, and visibility across distributed environments.

OT-Specific Services

Cisco’s commitment to OT includes the launch of tailored services that address the unique challenges of industrial systems. This focus highlights the importance of secure, integrated solutions in environments where downtime isn’t just inconvenient—it’s costly and disruptive.

Networking and Observability: Building Resilient Infrastructure

Cisco is transforming how networks are built, managed, and observed, ensuring they’re ready for the challenges of tomorrow.

Wi-Fi 7 and Network Automation

The introduction of Wi-Fi 7 access points sets a new standard for wireless networking, offering unmatched performance in high-density environments. Coupled with network automation tools, Cisco is enabling organisations to simplify operations and optimise performance in increasingly complex network ecosystems.

Observability with ThousandEyes

Cisco’s ThousandEyes observability platform integrates seamlessly across applications, networks, and infrastructure, delivering end-to-end visibility. This capability ensures organisations can quickly identify and resolve performance issues, supporting digital resilience in a hyperconnected world.

Unified Vision: One Cisco

Cisco’s strength lies in its ability to bring everything together—a true “One Cisco” approach. By combining its diverse portfolio into unified, integrated solutions, Cisco delivers value that exceeds the capabilities of individual technologies. This vision aligns perfectly with Orro’s mission to provide Securely Connected Everything for our customers.

Final Thoughts: Driving Innovation Together

Cisco’s vision, supported by its relentless innovation across AI, security, networking, and OT, sets the stage for a future defined by integrated, resilient technology. At Orro, we’re proud to partner with Cisco to bring these advancements to life for our customers.

If you’re ready to explore how these innovations can transform your organisation, reach out to us today. Together, we’ll build a secure, connected future.

Article written by Michael Van Rooyen, Chief Technology Officer, Orro

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But as digitalisation sweeps through the industrial landscape, the boundaries between IT and OT are blurring. Integrating these two can unlock significant benefits like operational efficiency, agility, innovation, and cost savings.

Despite the promise, merging IT and OT remains a tricky challenge for many organisations. However, with the right strategies and solutions, these challenges can be addressed, leading to a harmonious integration.

The clash of machines 

The rapid rise of technologies like Industrial IoT, cloud, and AI has made the lack of interoperability between OT and IT more pronounced than ever.

In industries like manufacturing, OT systems often consist of legacy equipment that was never designed to work with modern IT infrastructure. For example, software applications are frequently updated to keep pace with technological advancements, while industrial machinery can remain unchanged for years, sometimes even decades. This creates a significant compatibility gap.

The sheer diversity of OT assets adds another layer of complexity. Different communication protocols, varying standards, and a multitude of devices make it tricky for IT teams to create a unified environment.

To bring everything together, organisations need to invest in infrastructure that supports both IT and OT needs. For example, IoT middleware solutions act as bridges between disparate systems, translating protocols and facilitating communication.

Another way to harmonise IT and OT is by using open-source solutions and adhering to industry standards. Protocols like MQTT (Message Queuing Telemetry Transport) and OPC UA (Open Platform Communications Unified Architecture) are specifically designed to bridge the divide between IT and OT, ensuring they can communicate seamlessly.

The data deluge

Another challenge of IT and OT working in isolation is the data silos. This separation makes it tough for organisations to get a complete view of their operations, hindering decision-making.

When IT and OT finally do come together, they open up a floodgate of diverse data, including structured, semi-structured, and unstructured data. Managing all this data and extracting valuable insights is difficult without the right strategy and solutions in place.

Picture a factory equipped with IoT sensors, constantly feeding terabytes of data into their centralised IT system every single day. Without a robust data management strategy, valuable insights might get lost in the noise. Or, imagine a utility company that has smart metres hooked up to its data analytics platform. We’re talking millions of metres generating massive amounts of data that can quickly lead to inconsistencies and quality issues if not managed properly.

Edge computing solutions can help manage large volumes of data more efficiently. These advanced technologies process data closer to the source, reducing latency and boosting real-time decision-making.

A robust data governance framework is also essential for ensuring data quality and consistency. This means setting standards, policies, and procedures for data collection, storage, and usage. Regular data audits and validation processes will help ensure your data stays accurate and reliable.

The security tightrope 

Cybersecurity is a critical concern that intersects both IT and OT domains.

One big issue is that OT environments often rely on legacy systems that weren’t built with cybersecurity in mind. These outdated setups might not have the security features needed to fend off today’s cyber threats. When they’re connected to IT systems, they create more entry points for attackers if not properly secured. Given that downtime in OT can be a big problem, sometimes even endangering lives, the stakes are high.

Another challenge with IT and OT working independently is the lack of consistency in security policies and procedures. This divided approach can create protection gaps, where weaknesses in one area can affect the other.

To truly secure the whole organisation, it’s crucial to have a unified security strategy that covers both IT and OT environments. This should include implementing advanced security measures, such as encryption, endpoint protection, network segmentation, and intrusion detection systems. Conducting regular security assessments and updating security protocols are also critical for keeping up with evolving threats.

IT/OT convergence in action 

The integration of IT and OT systems is transforming businesses across various industries. Here are some hypothetical scenarios of IT and OT working together seamlessly in different settings.

Retail: Sync and stock

A fast-growing retailer decides it needs to optimise inventory management, with the ability to track inventory in real time, predict stock shortages, and autonomously reorder supplies.

On the OT side, shelves equipped with weight sensors and RFID tags detect low or out-of-stock items. These smart shelves continuously monitor stock levels, ensuring that products are available when customers want them, reducing the likelihood of lost sales opportunities. When there’s a sudden spike in demand, the IT system communicates this to the OT systems in the warehouse, allowing for immediate adjustments in operations to prioritise packing and shipping high-demand items, which is particularly crucial during peak shopping periods.

From the IT perspective, data from these sensors is transmitted to a central system for analysis. This system compiles all the information and sends alerts to store employees or automated replenishment systems. These alerts prompt immediate action, either by staff who physically restock the shelves or by autonomous systems that initiate the restocking process.

Manufacturing: The fast lane to efficiency

An automotive manufacturing plant faces unexpected downtime and delays due to complexities in their production line. By implementing digital twins, the plant creates a virtual replica of the physical production line, which is continuously updated with real-time data from sensors embedded in the machinery and equipment on the shop floor.

In this scenario, the IT team is responsible for setting up the digital infrastructure, including data collection, storage, and analysis systems. They ensure that the data flows seamlessly from the sensors to the centralised database and then to the digital twin model. This involves using advanced data analytics and machine learning algorithms to process the enormous volumes of data generated.

On the other hand, the OT team focuses on the physical aspects of the implementation. They install and maintain the sensors on the machines and work closely with the IT team to ensure accurate data collection. Their deep understanding of the machinery and production processes is crucial in interpreting the data and making informed decisions.

By working together, the IT and OT teams create a comprehensive digital twin system that allows the plant to monitor machine performance in real time, predict potential failures, and schedule maintenance activities proactively.

Energy: Harnessing the winds of change

In a region abundant with wind and solar resources, an energy provider aims to maximise the use of renewable energy. By integrating IT and OT, the organisation can effectively manage the unpredictable nature of renewable energy production, ensuring consistent power supply.

On the IT side, they use advanced weather forecasting systems to predict wind and solar patterns. This data is then connected to the OT systems controlling wind turbines and solar panels. When high wind speeds are predicted, the turbines adjust to capture as much energy as possible. Similarly, the angles of the solar panels are tweaked based on sunlight forecasts.

This integration also allows for real-time management of energy storage. When there’s excess energy during peak production times, it’s stored in batteries and released when production dips, ensuring a steady energy supply. This seamless blend of IT and OT not only optimises the use of renewable energy but also boosts grid stability and promotes sustainability.

Water: Safety from source to sip

A rural town relies on both groundwater and seawater for its water supply. Ensuring the quality of this diverse water source is crucial for public health and environmental conservation. To achieve this, the town’s water supplier sets up an integrated water quality monitoring system that combines IT and OT.

The OT infrastructure includes sensors placed at various points along the water supply chain, from groundwater wells to desalination plants. These sensors measure parameters such as pH, salinity, turbidity, and chemical contaminants.

The data collected is then sent to an advanced analytics platform that uses AI to assess water quality. For example, if there’s a sudden increase in chemical contaminants, the system can identify potential sources and suggest corrective actions. This allows the supplier to act quickly, ensuring water remains safe and clean for everyone.

Mining: Digging deep for insights

Imagine a mine where every piece of equipment, from the massive trucks to the tiniest sensors, is interconnected and communicating in real time. Thanks to IoT devices, data analytics platforms, and cloud computing, mines are evolving into complex networks where data flows effortlessly from the operational floor straight to the decision-makers’ desks.

With real-time data on ore grades and mineral composition, the extraction process is optimised. This ensures that only the highest quality ore gets sent for processing, maximising yield and reducing waste.

Meanwhile, there are drones flying high for aerial surveys and delivering detailed maps and 3D models of the mining site. These maps are integrated with autonomous haul trucks and drilling rigs to take over the dangerous jobs, removing the need for human operators in risky environments.

Wearable technology also comes into play, monitoring miners’ health and safety in real time. These devices track vital signs, detect hazardous gases, and offer real-time location tracking. If a miner shows signs of distress or enters a dangerous area, alerts are instantly sent to the control centre, enabling swift action.

Logistics: Trucking along smoothly

A logistics company is finding itself struggling with unexpected breakdowns and frequent delays with its fleet of delivery trucks. To overcome these issues, the organisation’s OT team fits the trucks with advanced telematics devices, which are linked to a central ERP system that’s managed by their IT department.

This smart, integrated setup allows the company to keep a watchful eye on various aspects of its fleet in real time — including vehicle performance, driver behaviour, fuel consumption, and even route efficiency — and take action as needed.

For instance, if a truck starts displaying signs of mechanical issues, the telematics system swiftly sends an alert to the maintenance team, who can then schedule repairs well before a breakdown occurs. Or, if the system detects unsafe driving behaviours, such as harsh braking and speeding, it provides instant feedback to encourage safe driving. The system also suggests the most efficient routes by analysing real-time traffic conditions and delivery schedules, helping to reduce both fuel consumption and delivery times.

Healthcare: Bridging IT and OT for better patient care

A large hospital is struggling with delays and potential errors in patient treatment due to poor data-sharing between its IT and OT systems. To tackle these issues, the hospital decides to introduce new IoT-enabled patient monitoring devices, which connect to a centralised electronic health record system.

These devices automatically log real-time data, such as heart rate, blood pressure, and oxygen levels, straight into the patient’s electronic health records. Nurses and doctors can then access the latest patient information from any device, making diagnoses quicker and more accurate.

This integrated system also sends automated alerts for any critical changes in a patient’s condition, allowing for rapid intervention and reducing the risk of complications. On top of that, the integration of predictive analytics helps healthcare professionals foresee potential health issues before they escalate, improving patient outcomes while boosting operational efficiency.

Making IT and OT work in harmony 

At Orro, we’re the experts in IT/OT integration across multiple industries, bringing to you state-of-the-art technologies, comprehensive managed services, and elite skills. Together, we can break down those walls between IT and OT and unlock a whole new world of operational excellence. Learn more about how we make great things happen

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