6 OT Cybersecurity Trends Defining Manufacturing Through 2026

Step into a modern manufacturing facility, and you’re stepping into a sea of data. From the hum of intelligent sensors to the precise pivot of robotic arms, every action is connected. This digital nervous system, powered by Operational Technology (OT), is the engine of smart manufacturing. However, every new point of connection also creates a new potential entry point for a cyberattack.

This isn’t just a hypothetical risk; it’s a top-of-mind concern for executives and plant managers alike. According to Rockwell Automation’s 10th Annual State of Smart Manufacturing Report—which surveyed 1,560 leaders across 17 manufacturing nations—cybersecurity now shares the stage with core metrics like safety, throughput, and cost.

The conversation has fundamentally shifted from “Should we invest in security?” to “How quickly can we demonstrate the ROI of our security investments?” With 96% of manufacturers planning to adopt cybersecurity platforms, resilience has become a powerful lever for profitability.

This article unpacks the six data-driven forces elevating OT cybersecurity from a compliance checkbox to the backbone of modern industry. Use these insights to benchmark your strategy, refine your metrics, and transform your security spending into a tangible operational advantage.

Trend 1: OT Security Platforms Become the Rule, Not the Exception

The Data: The era of debating OT security platforms is over. A staggering 64% of manufacturers already have one in place, and another 32% plan to deploy one within the next five years. Adoption is now a near-universal certainty.

With implementation as a given, the focus has pivoted to performance and payback. Executives are no longer asking if they need a platform, but what it can do for them. They want to know how many audit hours it can eliminate, how much it can reduce unplanned downtime, and how quickly it can secure the data streams needed for AI and advanced analytics. Teams that can successfully connect their security dashboards to established operational KPIs—like Overall Equipment Effectiveness (OEE) or Mean Time to Recovery (MTTR)—will have the most success securing budgets and proving value.

Your Action Plan:

• Establish Baselines: Before deployment, capture key performance metrics so you can show clear, undeniable ROI in your first quarterly review.
• Quantify Risk in Financial Terms: Translate technical achievements (like closed vulnerabilities) into business language (dollars saved by avoiding production loss) to resonate with finance leaders.
• Integrate Security Metrics: Feed OT security health data directly into production dashboards, proving that security is a driver of performance, not a drag on it.

Trend 2: Cybersecurity as a Catalyst for Smart Manufacturing ROI

The Data: For 53% of manufacturers, securing OT assets is a primary driver for new technology investments.

Cybersecurity is no longer just a defense mechanism; it’s an offensive strategy for growth. More than half of manufacturers are now adopting security at scale as part of their broader digital transformation. This recasts security leaders as essential enablers of innovation. By positioning hardened, secure networks as the necessary foundation for high-value initiatives like predictive maintenance, real-time energy management, or AI-driven quality control, risk reduction suddenly comes with a clear revenue upside. Upcoming regulations, such as NIS2 in Europe and CISA directives in the U.S., are only adding to the urgency.

Your Action Plan:

• Bundle Security with Automation Projects: Pair your security proposals with the ROI of a larger automation initiative to secure a bigger piece of the transformation budget.
• Collaborate with Innovation Teams: Co-author funding proposals with digital and R&D departments to tap into a wider pool of available capital.
• Leverage Regulatory Deadlines: Use compliance milestones as firm deadlines to anchor your project timelines and accelerate executive approvals.

Trend 3: Boardroom Scrutiny: Translating Cyber Risk into Business Impact

The Data: Cyber risk is a major external threat for manufacturers, with 30% of survey respondents ranking it among their most serious obstacles.

Executives, boards of directors, and the insurers who underwrite their risk are demanding a new language of risk—one measured in dollars and downtime, not just vulnerabilities. They expect clear answers to questions like: What is the projected financial loss if a key production line is hit by a cyber incident? How often are we running incident response drills, and what are we learning? Can you provide a clear, scored assessment of our security maturity across the entire OT environment? It is now the security leader’s job to translate technical details into business impact so that cybersecurity spending can be weighed effectively against other capital priorities.

Your Action Plan:

• Develop Financial Models for Cyber Incidents: Create clear financial scenarios (e.g., “cost of one day of downtime at Plant A”) so directors can grasp the financial exposure at a glance.
• Conduct Regular Tabletop Exercises: Run quarterly incident response drills to build muscle memory and identify gaps before an attacker—or an auditor—does.
• Engage Insurers Proactively: Involve your insurance partners in your control planning process to demonstrate maturity and potentially lock in better premiums.

Trend 4: The Rise of “Secure-by-Design” in Industrial Hardware

The Data: To combat risk at its source, 31% of manufacturers are prioritizing industrial hardware with embedded security controls.

The principle of “secure-by-design” is finally taking center stage on the plant floor. This means security is built-in, not bolted-on. Features like controller-level access controls, cryptographically signed firmware, and onboard security telemetry are becoming standard. While these deeper defenses offer far greater protection, they also require a new level of discipline in firmware lifecycle management and a shift in how assets are procured. Security specifications must be prioritized right alongside performance specifications.

Your Action Plan:

• Update Your Procurement Language: Mandate features like secure-boot and signed firmware in every Request for Quotation (RFQ) to future-proof all new assets.
• Systematize Firmware Management: Treat firmware updates with the same rigor as IT patching, complete with rollback plans and dedicated testing windows to prevent operational disruptions.
• Centralize Device-Level Monitoring: Ingest device-level security logs into your existing Security Information and Event Management (SIEM) platform for earlier threat detection and richer incident context.

Trend 5: Building a Cyber-Literate Workforce on the Factory Floor

The Data: Cyber skills are now non-negotiable. 81% of manufacturers place a high or top-tier priority on knowledge of cyber practices, and 47% rank these skills as “extremely important” when hiring.

The human element remains the most critical component of any security strategy. Leading manufacturers are actively working to build a cyber-literate workforce from the ground up. This includes embedding short “cyber safety moments” into shift handovers, funding professional certifications, and tying security performance (like patch compliance rates) to individual performance reviews. The goal is to make secure behavior as routine and automatic as traditional lockout/tagout safety procedures.

Your Action Plan:

• Incorporate ‘Cyber Moments’ into Daily Briefings: Use daily huddles to share short, relevant security tips that build awareness without disrupting production schedules.
• Incentivize Secure Practices: Publicly reward individuals and teams for good security hygiene, such as achieving incident-free quarters or rapid patch completion.
• Invest in Professional Development: Sponsor employees to earn role-relevant certifications (e.g., IEC 62443, CISM) to cultivate deep, in-house expertise.

Trend 6: The Final Frontier: Merging Cybersecurity into Your Safety Culture

The Data: Culture remains a primary obstacle. 25% of manufacturers cite employee resistance to change as a blocker, while another 25% point to a lack of cybersecurity awareness among senior leadership.

Ultimately, the most advanced technology is only as strong as the culture that supports it. Progress often stalls not due to a lack of knowledge, but due to a resistant mindset. Operators may view new security controls as a bottleneck to production, while managers are pressured to prioritize short-term output over long-term resilience. The solution is to embed cybersecurity into the organization’s broader safety culture. When cyber risks are discussed with the same gravity as physical safety risks, the entire organization’s perspective shifts.

Your Action Plan:

• Frame Cyber Risk as a Safety Issue: In all communications, discuss digital threats in the same breath as physical safety hazards to elevate their perceived importance.
• Celebrate Security Wins: Spotlight teams that achieve security milestones to normalize and reinforce good habits across the organization.
• Practice Integrated Incident Response: Run joint incident drills involving both IT and OT teams so that responders from both sides of the house know each other’s roles and playbooks before a real crisis hits.

Conclusion: From Afterthought to Advantage

Taken together, these six trends paint a clear and compelling picture: OT cybersecurity is no longer a siloed IT problem or a bolt-on afterthought. It is the essential connective tissue of modern, resilient manufacturing.

The companies that thrive in 2026 and beyond will be those that embrace universal platform adoption, tie security investments to business transformation, earn board-level trust through financial transparency, demand secure-by-design hardware, cultivate a cyber-literate workforce, and build a culture where safety and security are two sides of the same coin. Those who act now will not only shrink risk but will also accelerate innovation, build customer trust, and secure their competitive edge.

About the Data: The insights in this article are derived from Rockwell Automation’s 10th Annual State of Smart Manufacturing Report. The report analyzed feedback from 1,560 respondents in management and C-suite roles across 17 of the world’s top manufacturing countries. The survey included a diverse range of industries and company sizes, with revenues spanning from $100 million to over $30 billion, offering a comprehensive view of the global manufacturing landscape.