Industrial OT Cybersecurity Ransomware Surge: Manufacturing Under Attack in 2026

Introduction: The Ransomware Surge in Manufacturing

In the past 30 days, ransomware attacks have made headlines across the industrial sector, with manufacturing facilities experiencing unprecedented disruptions and production halts. According to the latest SANS Institute 2025 Survey (1), 80% of organizations have updated their incident response plans in direct response to the surge in OT-targeted ransomware. The numbers are stark: manufacturing saw a 61% increase in ransomware attacks, and critical infrastructure as a whole experienced a 34% rise, with threat groups like Qilin, Clop, Akira, Play, and SafePay leading the charge (KELA (4)).

While the headlines are alarming, the underlying trends reveal deeper systemic challenges—legacy system vulnerabilities, IT/OT convergence, and regulatory gaps—that demand a strategic, research-driven response.

The Anatomy of Industrial OT Cybersecurity: Why Manufacturing Is at Risk

Manufacturing environments are uniquely vulnerable due to their reliance on legacy OT systems, complex supply chains, and the increasing integration of IT and OT networks. The TXOne Networks guide (2) details how Human-Machine Interfaces (HMIs), Remote Terminal Units (RTUs), and SCADA systems, often designed for reliability rather than security, have become prime targets for attackers. These systems typically lack modern security controls, making them susceptible to lateral movement and privilege escalation once an attacker gains a foothold.

A key challenge is asset visibility. According to Dragos (7), 61% of industrial organizations struggle to monitor their critical assets effectively. This lack of visibility hampers threat detection and incident response, leaving organizations blind to both known and emerging threats. Asset discovery and contextual understanding are now recognized as foundational steps in any OT cybersecurity program (Dragos (7)).

The SANS survey further reveals that only 14% of organizations feel fully prepared for current OT threats, with remote access accounting for 50% of incidents, but only 13% deploying advanced controls (SANS Institute (1)). This gap between risk and readiness is driving urgent investment in asset visibility, threat detection, and secure remote access.

Double-Extortion Ransomware: Tactics, Threat Groups, and Impact

The evolution of ransomware tactics has made attacks more disruptive and costly for manufacturers. In 2025, double-extortion became the norm: attackers not only encrypted critical OT systems but also exfiltrated sensitive data, threatening public release unless ransoms were paid (KELA (4)).

Manufacturing was the hardest-hit sector, with a 61% surge in attacks and production downtime often measured in millions of dollars per day. Threat groups such as Qilin, Clop, Akira, Play, and SafePay have refined their techniques, exploiting remote access vulnerabilities and leveraging supply chain partners to gain initial entry (KELA (4)).

National security concerns are now front and center, as ransomware-induced production halts ripple through critical supply chains. The Norsk Hydro breach remains a cautionary tale: a single ransomware event can disrupt global operations, damage reputations, and trigger regulatory scrutiny (TXOne Networks (2)).

IT/OT Convergence: The New Attack Surface

The convergence of IT and OT networks has expanded the attack surface, introducing new risks and operational complexities. As Rockwell Automation (5) notes, bridging the IT/OT divide is now a top priority, but also a persistent challenge. Legacy OT systems, often decades old, are being connected to modern IT networks for efficiency and data analytics—yet these connections frequently lack adequate segmentation and security controls.

Operational priorities can conflict with security best practices. For example, production uptime may take precedence over patching vulnerable systems, leading to the accumulation of risk (Cyber Defense Magazine (10)). Asset discovery and risk assessment must account for both IT and OT assets, requiring collaboration between IT security teams and OT engineers.

The SANS survey highlights that investment in secure remote access (45%) and network segmentation (32%) is rising, but resource constraints remain a barrier (OPSWAT/SANS (9)).

Regulatory and Compliance Pressures: Frameworks and Gaps

Regulatory compliance is both a driver and a challenge for OT cybersecurity. Key frameworks such as NERC CIP, NIST Cybersecurity Framework, IEC 62443, and CMMC are shaping security strategies across manufacturing, energy, and critical infrastructure sectors (Microminder CS (3)).

Compliance implementation typically follows a structured approach:

• Asset identification and inventory

• Security planning and control implementation

• Continuous monitoring and testing

However, gaps persist. Many organizations struggle to map legacy OT assets to compliance requirements, and the pace of regulatory change can outstrip internal capabilities. Only 14% of organizations feel fully prepared for current threats, underscoring the need for ongoing investment in compliance-focused security measures (SANS Institute (1)).

The ISA/IEC 62443 framework (6) offers a risk-based approach, emphasizing security zones, conduits, and compensating controls tailored to industrial environments. Yet, adoption remains uneven, particularly among small and mid-sized manufacturers.

Strategic Security Restructuring: Best Practices for 2026 and Beyond

With ransomware threats escalating and compliance demands intensifying, manufacturers are rethinking their security strategies. Studies show that 50% of organizations prioritize investment in asset visibility, 45% in secure remote access, and 32% in network segmentation (OPSWAT/SANS (9)).

Best practices for industrial OT cybersecurity in 2026 include:

• Comprehensive Asset Discovery: Automated, non-invasive asset discovery tools provide a real-time inventory of all OT devices, supporting both security and compliance (Dragos (7)).

• Layered Defense: Implementing defense-in-depth strategies, including segmentation, access controls, and continuous monitoring, reduces the risk of lateral movement and ransomware propagation (Cyber Defense Magazine (10)).

• Secure Remote Access: Deploying multi-factor authentication (MFA), role-based access, and encrypted connections for all remote sessions mitigates one of the most common attack vectors (Thermo Fisher Scientific (8)).

• Incident Response Planning: Regularly updating and testing incident response plans ensures readiness for ransomware and other OT-targeted attacks (SANS Institute (1)).

• Continuous Monitoring and Auditing: Real-time monitoring of network traffic and user activity, combined with regular audits, helps detect and contain threats before they escalate (Thermo Fisher Scientific (8)).

And, of course, don't forget to patch your legacy systems—because nothing says "welcome" like an unpatched PLC from 2003.

Forward-thinking companies, including Red Sentry, are building for this new reality by combining human-led penetration testing with continuous automated vulnerability scanning and compliance support tailored to industrial environments.

Conclusion: The Path Forward for Industrial OT Cybersecurity

The surge in ransomware attacks on manufacturing is not a passing storm—it's a structural shift in the threat landscape. As IT and OT systems become more interconnected, the attack surface will only grow, and adversaries will continue to innovate. The path forward demands a holistic approach: asset visibility, layered defense, secure remote access, and rigorous compliance must become standard practice, not afterthoughts.

Regulatory frameworks will continue to evolve, and organizations that invest in proactive security and compliance will be best positioned to weather the next wave of threats. The future of industrial OT cybersecurity hinges on collaboration between IT and OT teams, executive commitment, and the adoption of advanced, adaptable security solutions.

Don't Let Hackers Control Your Safety Systems

Ransomware is no longer a distant threat—it's a daily reality for manufacturers worldwide. Don't wait for an incident to expose your vulnerabilities. Schedule a demo with Red Sentry to see how our human-led penetration testing and continuous vulnerability management can help you secure your industrial operations for 2026 and beyond. Contact us today to take the first step toward resilient OT cybersecurity.

References

1. SANS Institute 2025 Survey: OT Cybersecurity Incidents Rising as Ransomware and Remote Access Risks Grow

2. OT Cybersecurity: The Guide to Securing Industrial Systems - TXOne Networks

3. Regulatory Compliance and OT Cybersecurity: What You Need to Know - Microminder CS

4. Half of 2025 Ransomware Attacks Hit Critical Sectors - KELA

5. Top OT Security Challenges and How to Address Them - Rockwell Automation

6. Understanding ISA/IEC 62443: A Guide for OT Security Teams - Dragos

7. What Is Asset Visibility and Why Does It Matter? - Dragos

8. Best Practices for Enhancing Security in Industrial Control Systems - Thermo Fisher Scientific

9. 2025 ICS/OT Cybersecurity Budget: Spending Trends, Challenges, and the Future - OPSWAT/SANS

10. The OT Cybersecurity Challenge: Navigating the Journey to A Secure Industrial Future - Cyber Defense Magazine