Breaking Free from Outdated OT Practices: Top 5 Risks Threatening Manufacturing & Distribution

Breaking Free from Outdated OT Practices: Top 5 Risks Threatening Manufacturing & Distribution

The manufacturing and distribution sectors are on the brink of transformation, driven by Industry 4.0, the Industrial Internet of Things (IIoT), and digital initiatives designed to increase connectivity, data-driven decision-making, and agility. However, many organizations still rely on outdated operational technology (OT) methods, creating vulnerabilities that compromise productivity, security, and future competitiveness. Here, we explore the top five risks associated with maintaining the OT status quo in manufacturing and distribution environments.

1. Crippling Downtime and Its Costly Impacts

Unplanned downtime is costly, with 67% of organizations reporting losses of over $1 million per hour, according to Copia’s State of Industrial DevOps Report. Companies that depend on ad-hoc fixes and manual processes are especially vulnerable, as errors in code deployment or system changes can halt entire production lines and disrupt the supply chain. Adopting Industrial DevOps practices, including automated backups and centralized code repositories, can drastically reduce downtime, ensuring smoother, more reliable operations.

2. Escalating Cybersecurity Risks

The blending of IT and OT environments has expanded the attack surface for cyber threats, with 47% of unplanned downtime in the industry now attributed to cybersecurity incidents. A lack of real-time visibility and a fragmented security approach leave organizations exposed to ransomware attacks, data breaches, and other malicious threats. Industrial DevOps, integrating DevSecOps principles, builds security into every phase of deployment, making OT systems more resilient against cyber risks.

3. Stifled Innovation and Reduced Agility

Outdated practices in OT hinder companies’ ability to innovate and respond to market demands. Manual processes, extended development cycles, and siloed teams prevent rapid adaptation, risking market relevance as competitors evolve. Industrial DevOps fosters continuous improvement and collaboration, allowing for faster product development, customized solutions, and a nimble response to market changes, positioning companies to lead rather than lag.

4. Workforce Challenges and Skills Gaps

As experienced workers retire and new talent faces complex OT systems, the skills gap in manufacturing and distribution continues to widen. The status quo, with its reliance on manual processes, makes onboarding and knowledge transfer challenging. Industrial DevOps can alleviate workforce strain by automating routine tasks and enhancing collaboration, enabling teams to focus on high-value, innovative work rather than redundant, manual activities.

5. Missed Opportunities for Growth and Efficiency

Relying on outdated OT practices means organizations miss out on significant productivity and profitability gains. Industrial DevOps optimizes operations by streamlining workflows and integrating AI-driven insights to improve efficiency and support data-informed decisions. By breaking down silos and implementing advanced technologies, companies unlock new levels of growth potential and competitive advantage.

Conclusion

The risks associated with the OT status quo in manufacturing and distribution are clear: costly downtime, increased cybersecurity vulnerabilities, limited innovation, workforce challenges, and lost growth opportunities. As the industry becomes more competitive and digitally driven, embracing Industrial DevOps principles will be essential. By moving away from outdated practices, organizations can build a secure, agile, and resilient operational foundation for the future. The time to act is now.

This article was originally published here.

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