Are the measures taken against the risk levels that arise as factories expand outward sufficient?

In an interview with Wise TV, Ediz Öztürk, the founder of edZconsult, details the historical evolution and integration processes of IT (Information Technology) and OT (Operational Technology) systems, as well as the reasons why the isolation between these systems is critical. He also addresses topics such as industrial security, update challenges, security vulnerabilities in SCADA systems, and defense methods at the physical layer.

For years, OT and IT systems were viewed as distinct entities. Particularly during the Third Industrial Revolution in the 1970s—driven by advancements in automation and robotics, especially in Japan—OT systems began to shift toward “embedded systems.” These systems were designed to execute specific functions rapidly while minimizing latency. Initially, as you mentioned, these systems operated in isolation. However, we were ultimately unable to maintain that isolation from the IT world, leading to the convergence of IT and OT. With the advent of the Fourth Industrial Revolution—and the rise of the Industrial Internet of Things (IIoT)—the concept of isolation is no longer the primary focus; instead, we must seriously consider how developments in the IT realm impact the OT landscape. While the classic seven-layer OSI model in IT traditionally incorporated specific isolation measures—starting from the physical layer and moving up—modern requirements have changed. Today, remote work and the operations within smart factories—spanning production facilities and assembly lines—demand deep integration. Consequently, it is no longer feasible for industrial systems to operate in isolation. Therefore, implementing robust isolation strategies during the convergence of IT and OT is essential. To what extent is this actually being done? We are actively engaged in various initiatives in this area, including specific projects focused on industrial systems, particularly SCADA systems. A wide range of activities is carried out here, from penetration testing to Red Teaming. However, we often observe that necessary updates are not performed—partly because the systems must operate 24/7, a necessity driven by economic factors. Shutting down a factory or industrial facility for any significant period is rarely an option. Consequently, we frequently see that essential updates are neglected. Let us now consider the issue of proper isolation. We need to look at this from an IT perspective as well, given that we frequently implement isolation in IT systems—particularly at Level 4. Unfortunately, I see this pattern often. Yet, we absolutely must implement isolation at both Level 3 and Level 2 as well. From a technical standpoint, for instance, VLANs need to be utilized much more effectively. Furthermore, in the cybersecurity world, we tend to think only in terms of TCP/IP protocols; however, when we examine industrial protocols, we find they are vastly different. We operate using standards that far exceed standard 802.11 protocols, making the use of correct protocols and appropriate levels of isolation absolutely critical. But is this actually happening? No; in the various projects we undertake, it is evident that organizations are not taking sufficient precautions. So, what must be done? IT and OT must be considered under a unified framework, adopting a holistic approach that incorporates isolation strategies across the entire architecture—from the highest levels down to the lowest. Of course, when we speak of isolation here, we do not mean a complete disconnection; rather, the focus is on ensuring that only the correct protocols are permitted to pass. We recently conducted a project involving an air traffic control system, for example. Here, too, we ensured that traffic flows in only one direction within specific areas—or specific networks, let’s say. This enabled us to intervene against potential external intrusions at the physical level—let alone at layers 2, 3, or 4. Therefore, when considering industrial systems, it is crucial that we implement proper isolation at every layer, including the physical layer.

The Evolution of Industrial and IT Systems

For years, industrial and IT systems were viewed as separate entities and evolved in distinct domains. However, with the advent of the Third Industrial Revolution in the 1970s, the development of automation and robotics paved the way for the convergence of these two systems. The emergence of embedded systems—particularly in Japan—enabled industrial systems to operate with reduced latency and shorter processing times. These developments made the integration of IT and OT systems inevitable.

The Rise of Embedded Systems

Embedded systems are computer systems designed to perform specific functions, typically integrated within a larger device. These systems have become a cornerstone of industrial automation. Key advantages of embedded systems include low latency and high efficiency; however, their isolation from the IT world can lead to security vulnerabilities.

The Integration of IT and OT Systems

With the Fourth Industrial Revolution in the 2000s, the integration of IT and OT systems gained further importance. The concept of the Industrial Internet of Things (IIoT) emerged as part of this integration. Merging IT and OT systems facilitates a more efficient and integrated manufacturing process; however, issues regarding security and isolation must be carefully addressed during this integration.

The Importance of Security and Isolation

The integration of IT and OT systems can introduce security vulnerabilities. Therefore, ensuring proper system isolation and the implementation of robust security protocols is of critical importance. Isolation measures implemented across the layers of the OSI model are used to enhance system security. However, the adequacy of these measures must be continuously evaluated.

Industrial Protocols and Standards

Protocols used in industrial systems differ from the TCP/IP protocols widely used in the IT world. Therefore, the selection and implementation of appropriate protocols are critical for system security. Beyond standards such as 802.11, industrial protocols offer superior security and efficiency.

Future Trends and Initiatives

The integration of IT and OT systems will become increasingly important in the future. New methods and technologies are being developed to ensure system security throughout this process. Activities such as penetration testing and Red Teaming are employed to identify and remediate system vulnerabilities. Furthermore, continuous system updates and monitoring are crucial for maintaining security.

Conclusion

The integration of industrial and IT systems has become an indispensable part of modern manufacturing processes. While this integration enables a more efficient and cohesive production process, it also necessitates careful attention to security and isolation. The use of appropriate protocols and continuous system monitoring are vital for ensuring security in this context. In the future, the integration of IT and OT systems will become even more widespread, driving the development of new technologies and methods in this field.