Global OT Network Segmentation for Cyber Risk Reduction

Overview

TDI Vertical partnered with a multinational manufacturing organization to design and implement a scalable, secure Operational Technology (OT) network segmentation strategy. The project’s goal was to reduce cyber risk, protect critical industrial systems, and achieve compliance with international standards across over a dozen global production facilities.

This initiative became a cornerstone of the client’s broader cybersecurity transformation, reinforcing system resilience without disrupting manufacturing operations.

Business Challenge

The client—a global manufacturer with more than 10,000 employees across multiple continents—faced increasing threats targeting its OT environment. Key challenges included:

• Lack of Visibility
  OT environments operated in isolation with limited insight into traffic patterns, assets, or interdependencies.
• Flat Network Architecture
  Absence of segmentation allowed unrestricted lateral movement, raising the risk of widespread impact during an incident.
• Operational Sensitivity
  Any changes to production systems had to be made without impacting uptime or disrupting time-sensitive processes.
• Global Scale
  Security strategy had to be standardized, yet flexible enough to address diverse operational setups across sites.

The client turned to TDI Vertical for a comprehensive, scalable segmentation framework that could be deployed with minimal risk to operations.

Solution & Design

TDI Vertical applied a methodical approach to network segmentation across IT and OT boundaries, including:

• Current-State Assessment
  Conducted traffic analysis, asset inventory, and communication mapping across multiple representative sites.
• Risk-Based Segmentation Architecture
  Developed a layered model using VLANs, firewalls, and access control lists to segment critical assets and isolate functions.
• Zero Trust Framework
  Designed segmentation with identity- and role-based access principles at the core.
• Site-Specific Customization
  Adjusted controls based on unique operational workflows and legacy system requirements.
• Phased Global Rollout
  Deployed segmentation in stages to ensure business continuity and fine-tune policies through real-time validation.
• Cross-Team Integration
  Facilitated strong collaboration between IT, OT, and plant operations to ensure seamless design, adoption, and support.

Unique TDI Vertical Contributions

TDI Vertical’s deep expertise in industrial cybersecurity enabled delivery of a solution that balanced control with operational flexibility. Key contributions included:

• Proprietary Assessment Framework
  Enabled rapid identification of high-risk assets and communication pathways.
• Combined IT/OT Strategy
  Bridged knowledge and culture gaps between corporate IT and plant-level OT teams.
• Global Template, Local Execution
  Created a master architecture with customizable playbooks for consistent deployment across all sites.
• Documentation & Knowledge Transfer
  Produced detailed diagrams, runbooks, and training resources for internal teams to maintain and evolve the solution.

Results & Impact

The global OT segmentation initiative delivered tangible cybersecurity and operational improvements across the client’s manufacturing sites:

• Enhanced OT Visibility
  Achieved a 70% increase in visibility of operational assets and communication flows, enabling better monitoring and management.
• Reduced Lateral Threat Risk
  Implemented micro segmentation and zone-based controls, leading to a 60% reduction in potential lateral attack paths.
• Zero Production Downtime
  Phased implementation allowed all segmentation to be introduced without disrupting active manufacturing systems.
• Accelerated Incident Response
  With improved asset mapping and network isolation, incident containment times were significantly reduced.
• Stronger Executive Confidence
  Clear results and risk reduction metrics helped secure leadership support for broader OT cybersecurity investments.
• Established Reference Architecture
  The segmentation model became a global standard and is now used for all new sites and modernization efforts.

This success positioned the organization to maintain a strong security posture while continuing to scale operations globally—with cybersecurity integrated into their core operational strategy.

Ongoing Impact

The collaborative governance and training model built during this engagement became a template for future OT security projects. TDI Vertical continues to support:

• Regular segmentation health assessments
• Security control tuning as operational needs evolve

The success of this project has driven increased investment in cybersecurity from senior leadership and helped embed security into the culture of the client’s global manufacturing operations.