Operational technology (OT) environments are becoming increasingly complex, comprising programmable logic controllers (PLCs), supervisory control and data acquisition systems (SCADA), industrial networks and cybersecurity frameworks. As a result, many manufacturers rely on a mix of vendors, in-house teams and third-party service providers to manage these varied components.
The downside is that this fragmented approach often results in inefficiencies, extended downtime and slower incident resolution.
A more effective approach is to use an integrated OT-managed services approach led by control systems integrators. By managing control systems (PLCs, SCADA, HMIs) and the supporting OT infrastructure (networks, cybersecurity, cloud integrations), control systems integrators can ensure seamless operations, faster troubleshooting and enhanced security. This unified approach is crucial to reducing downtime, optimizing production and improving overall plant resilience.
Accelerating issue resolution
When multiple vendors support OT systems, troubleshooting becomes a prolonged and inefficient process. A malfunction in a SCADA system might be blamed on a PLC misconfiguration, while network failures could be attributed to IT-related infrastructure. This siloed approach creates delays as different teams pass responsibility back and forth.
Control systems integrators, on the other hand, provide a single point of accountability. A unified OT-managed services team quickly identifies root causes and implements resolutions because they have complete visibility into the industrial control systems and the underlying infrastructure.
Beyond the SCADA example noted above, other common OT problems that can be addressed by unified OT-managed services team include:
- Network failures: Many manufacturers rely on legacy network infrastructure that is not optimized for modern OT needs. If IT and OT teams lack cross-functional knowledge, a failure in an industrial switch or a VLAN misconfiguration can take hours to diagnose. A control systems integrator, however, has expertise in both industrial networking and control systems, allowing for rapid diagnosis and resolution.
- Cybersecurity threats: Industrial control systems are prime targets for cyberattacks, such as ransomware or unauthorized access attempts. A unified OT-managed services provider ensures real-time monitoring, quick containment and mitigation strategies to minimize the impact of breaches.
Using proactive maintenance and predictive analytics to prevent downtime
Reactive maintenance models are no longer sufficient. Waiting for equipment failures to occur before addressing them results in lost production hours and increased costs. Control systems integrators bring proactive maintenance strategies that leverage predictive analytics and real-time monitoring to prevent issues before they disrupt operations.
Three main services applied by control systems integrators to prevent downtime are:
- Predictive analytics: By analyzing historical performance data from PLCs, supervisory control and data acquisition systems, as well as network components, control systems integrators can detect early warning signs of failure, such as increased cycle times, sensor drift or communication errors.
- Automated alerts and remote monitoring: Continuous monitoring of OT systems allows integrators to identify deviations in system performance and send automated alerts, prompting preemptive action before a slight anomaly escalates into a full-scale failure.
- Patch management and compliance: Keeping OT systems up to date is critical, but improper patching can lead to compatibility issues. Control systems integrators ensure firmware updates and security patches are deployed methodically, minimizing risk and maintaining regulatory compliance.
Improve cybersecurity through faster incident response
Cyber threats targeting OT environments have surged, with incidents like the Colonial Pipeline attack underscoring the vulnerabilities of industrial control systems. Unlike traditional IT threats, OT cyber incidents can have catastrophic real-world consequences, from production shutdowns to safety hazards.
A fragmented support model slows cyber incident response, as IT teams focus on corporate security while OT teams prioritize plant uptime. Control systems integrators bridge this gap by integrating cybersecurity into managed OT services, ensuring real-time threat detection and rapid containment.
Control systems integrator responses to real-world cyber threats include:
- Ransomware: Attackers increasingly target OT assets to halt production and demand ransoms. A control systems integrator with continuous monitoring capabilities can detect abnormal traffic patterns, isolate compromised assets and implement network segmentation to prevent lateral movement.
- Unauthorized access: Insecure remote access technologies pose significant risks. Control systems integrators implement secure remote access protocols, enforce multi-factor authentication and monitor for unusual access attempts to prevent unauthorized control of critical processes.
- Supply chain: Third-party software updates or device firmware can introduce malware into an OT environment. Control systems integrators vet and test all updates in a controlled environment before deploying them to production systems, ensuring security and functionality.
Seamless updates to reduce disruptions
OT environments require careful handling when deploying updates, as unplanned downtime caused by software changes can significantly impact production. Unlike IT, where updates can be scheduled with minimal disruption, OT updates must be managed precisely to avoid interfering with real-time control systems.
Here, control systems integrators oversee:
- Change management procedures: A structured approach ensures updates are thoroughly tested and validated before deployment to prevent unexpected failures.
- Version control and backup strategies: Control systems integrators maintain detailed version control and rollback plans, ensuring systems can be restored quickly if an update introduces issues.
- Minimal production interruption: Updates are scheduled during planned maintenance windows or in a way that minimizes impact on critical operations, reducing downtime and optimizing production efficiency.
Marty Van Der Sloot is director of operational technology at Interstates, a certified member of the Control System Integrators Association (CSIA). For more information about Interstates, visit its profile on the Industrial Automation Exchange.
