There is a big difference between managing laptops in an office and protecting control systems on a factory floor. On paper, both fall under “IT.” In real life, the moment you step into operational technology and industrial control systems, a lot of traditional IT managed services stop working the way people expect them to.
The factory floor does not behave like an office network. The priorities are different. The risks are different. The rules are different. And if managed services teams treat OT and ICS the same way they treat corporate IT, problems show up fast.
This is the reality many manufacturing teams face. The good news is, the breaks are fixable.
Why IT Managed Services Struggle in OT and ICS Environments
Most IT managed services are built around confidentiality, data protection, and uptime for business systems. OT and ICS care first about safety, availability, and continuous operation. Data protection still matters, but stopping a production line or causing unsafe machine behavior can be catastrophic.
Here is where the cracks usually appear.
1. Patching and Updates Collide With Production Schedules
In IT, patching is routine. Systems get updated monthly, sometimes weekly, sometimes immediately for critical threats.
On the factory floor, that approach can shut down production or break certified systems.
Many control systems are:
- Running on legacy operating systems
- Certified for specific software versions
- Sensitive to timing and performance changes
An IT provider pushing standard patch cycles without production coordination often creates downtime, equipment faults, or safety alarms.
2. Security Tools Overload Control Networks
Traditional endpoint security, network scanners, and monitoring agents are designed for business networks. When those same tools touch PLCs, HMIs, or SCADA networks, they can overload fragile communications or disrupt real-time control traffic.
A vulnerability scan that is harmless in IT can freeze an HMI or drop communication with a controller on the shop floor.
3. Lack of OT Context Leads to Dangerous Decisions
Many IT teams do not understand:
- Process safety requirements
- Control system dependencies
- Equipment certification constraints
- Regulatory compliance tied to machine behavior
Without that context, simple decisions like rebooting a server, isolating a segment, or blocking traffic can cause production loss, quality issues, or even physical risk.
4. Incident Response Playbooks Do Not Fit Industrial Systems
When a security event happens in IT, response often means isolating systems, shutting down connections, and restoring from backup.
In OT, that can stop production for days or damage equipment. Some systems cannot simply be “restored.” Some processes cannot be paused mid-cycle. Many industrial assets do not even support modern backup methods.
How to Fix the IT–OT Gap
The solution is not abandoning managed services. The solution is adapting them to the reality of industrial operations.
1. Build an OT-Aware Governance Model
Before touching a factory network, managed services must align with:
- Operations teams
- Engineering teams
- Safety officers
- Compliance requirements
Every decision should answer one question first:
Does this maintain safe and reliable production?
Security and IT improvements must serve that goal, not conflict with it.
2. Separate IT and OT Networks Properly
Flat networks are a common source of failure. The fix is clear segmentation:
- Business IT zone
- DMZ or industrial demilitarized zone
- Control zone
- Safety zone
This structure allows IT teams to secure business systems aggressively while protecting sensitive control networks from unnecessary scanning, patching, and monitoring traffic.
3. Change the Patching Strategy
Patching in OT should be:
- Risk-based
- Scheduled with production
- Tested in simulation environments
- Documented for compliance
Emergency patching is rare on the factory floor. Instead, vulnerabilities are mitigated through network controls, access restrictions, and monitoring until scheduled maintenance windows allow updates safely.
4. Use OT-Safe Monitoring and Detection
Visibility is still essential. But the tools must be built for industrial protocols and low-impact monitoring.
Passive network monitoring, protocol-aware sensors, and behavior-based anomaly detection provide security insight without disrupting control communications.
5. Create Industrial-Specific Incident Response Plans
Response plans for OT must consider:
- Production continuity
- Equipment safety
- Regulatory obligations
- Environmental risks
- Physical access to systems
The goal becomes contain, stabilize, and continue operations safely, not simply “shut it down and clean it up.”
6. Train Managed Services Teams in OT Fundamentals
Even basic training in:
- Control system architecture
- Industrial networking
- Safety instrumented systems
- Process automation principles
…dramatically reduces the chance of mistakes.
When IT professionals understand what the machines actually do, their decisions become far safer and more effective.
The Real Outcome: Stability, Security, and Trust
When IT managed services are adapted correctly for OT and ICS, something important happens. Operations teams stop seeing IT as a threat to production. Security teams stop feeling blind inside the plant. Leadership gains confidence that both business systems and factory systems are protected without sacrificing output.
The factory floor becomes more resilient. Cyber risk decreases. Downtime becomes more predictable. Safety improves.
That is the real goal. Not just stronger security. Not just better IT.
But a factory that runs safely, efficiently, and reliably in a world where both machines and networks matter equally.
This post was written by a professional IS Technology. IS Technology is a trusted Managed Services Provider (MSP) and business technology partner serving Western North Carolina. We provide comprehensive solutions in managed IT services near you, cloud infrastructure, cybersecurity near you, document management, and managed print services—helping organizations stay secure, streamlined, and productive.
