Rockwell Automation reduces OT security costs with SecureOT platform

A global pharmaceutical manufacturer implemented the SecureOT Platform from Rockwell Automation to address operational technology (OT) security challenges across 55 facilities, achieving significant cost reduction and improved threat response capabilities.

The deployment focused on replacing fragmented IT-based security tools with an OT-specific platform designed to manage industrial environments with high availability requirements.

Fragmented security tools and limited visibility
The manufacturer initially relied on IT-oriented security systems that did not align with OT requirements such as uptime and process continuity. This resulted in incomplete monitoring of industrial assets and limited visibility into network activity.

Without a comprehensive asset inventory, the organization faced challenges in identifying vulnerabilities, applying patches, and responding to threats in a timely manner.

Manual processes for asset tracking, patching, and risk assessment required significant labor input and increased the likelihood of errors. These activities consumed substantial resources across multiple sites operating under strict regulatory frameworks.

Phased deployment and system integration
The implementation began with a pilot deployment in four facilities to validate system performance and integration. Following this phase, the platform was expanded to cover the remaining sites.

A structured assessment of existing systems, processes, and security gaps was conducted to define the deployment strategy and ensure compatibility with operational requirements.

The rollout followed a centralized strategy with local execution, enabling consistent security standards while accommodating site-specific conditions.

Automation of security workflows
The SecureOT Platform automates key functions including asset discovery, inventory management, vulnerability assessment, and contextual risk scoring.

Automation reduces reliance on manual processes and enables continuous monitoring of OT environments. Network segmentation, access control enhancements, and backup improvements were also implemented to strengthen system resilience.

Threat detection and response processes were accelerated from multi-day timelines to near real-time action, reducing exposure to potential incidents.

Measurable operational improvements
The deployment resulted in a 70% reduction in OT security-related labor costs, corresponding to annual savings of approximately $700,000. Automation also reduced the need for manual work previously estimated at $1 million per year.

Full visibility across all facilities enabled prioritization of risks based on impact, allowing more efficient allocation of resources.

The organization transitioned from reactive incident response to proactive risk management, supported by continuous monitoring and faster remediation capabilities.

Impact on compliance and operational efficiency
The platform supports regulatory compliance by integrating security processes with existing operational workflows. Automated reporting and structured change management simplify audit processes and ensure adherence to industry standards.

By reducing the workload associated with security management, engineering resources were reallocated to production and other operational activities.

The implementation demonstrates how an integrated OT security platform from Rockwell Automation can improve visibility, reduce operational costs, and enhance cybersecurity resilience in regulated manufacturing environments.

Edited by Natania Lyngdoh, Induportals Editor — Adapted by AI.

www.rockwellautomation.com