Converged IT/OT Cybersecurity Architecture for an Advanced Manufacturer
CYVERRA designed and deployed a comprehensive operational technology (OT) security framework across eight regional production plants. The programme established Purdue-model network micro-segmentation, zero-trust remote access, and real-time industrial threat detection.
Specialised component and industrial equipment manufacturer
- 100%
- OT asset visibility
- -74%
- Mean time to detect anomalies
- 0
- Unauthorised lateral paths
- IEC 62443
- Standard compliance
The Challenge
The manufacturer operated across eight automated production facilities where legacy operational technology (OT) had progressively converged with enterprise IT systems. Industrial control systems (ICS), programmable logic controllers (PLCs), and supervisory control and data acquisition (SCADA) networks were insufficiently isolated from corporate networks, creating severe exposure to lateral malware propagation. Asset visibility across shop-floor environments was fragmented. Field engineers relied on unmonitored third-party remote access tools for machine maintenance, while critical production assets operated on legacy operating systems that could not support endpoint security agents or standard patching cadences. Without centralised telemetry or automated anomaly detection in the OT domain, the client faced mounting supply-chain audit pressure and the latent risk of operational disruption caused by uncontained cyber incidents.
Our Approach
CYVERRA initiated the engagement with passive network discovery and vulnerability profiling to map all connected industrial assets and industrial communication protocols (Modbus, Profinet, EtherNet/IP) without disrupting continuous manufacturing operations. Our engineering team architected a multi-layered defence aligned with the IEC 62443 standard and the Purdue Enterprise Reference Architecture. We implemented next-generation industrial firewalls to enforce micro-segmentation between production cells, safety instrumented systems, and enterprise business applications. Privileged Access Management (PAM) with just-in-time access controls and session recording was deployed for internal engineers and third-party equipment vendors. To ensure proactive incident detection, CYVERRA integrated continuous OT network monitoring platforms with the client's central Security Information and Event Management (SIEM) system. This provided security operations personnel with unified visibility, automated protocol anomaly detection, and contextual playbooks for rapid containment of operational anomalies.
The Outcome
The implementation established total visibility across all industrial endpoints and eliminated unmanaged lateral paths between the corporate network and production floors. The organisation successfully achieved compliance with IEC 62443 requirements, strengthening assurance for enterprise supply-chain partners. Threat containment capabilities were transformed; security analysts can now isolate anomalous OT segment traffic in minutes rather than hours, preventing production line shutdowns while maintaining full auditability of all vendor maintenance sessions.
Technology used
- Palo Alto Networks NGFW
- Claroty CTD
- Microsoft Sentinel
- CyberArk PAM
- Cisco ISE
- Fortinet FortiGate
CYVERRA established complete visibility over our operational technology environment without causing a single minute of production downtime.