Fortinet: AI Detection Reshaping Manufacturing Security

As operational technology (OT) networks expand, manufacturers are turning to AI and machine learning to combat sophisticated cyber threats. Fortinet's latest research reveals how AI-powered monitoring systems are helping industrial operations cut incident rates and protect critical infrastructure.

The convergence of IT and OT has created unprecedented vulnerabilities in manufacturing environments. As factories digitalise production lines and connect increasing numbers of devices, cyber threats that once targeted corporate IT systems are now reaching the factory floor.

According to Fortinet's 2025 State of Operational Technology and Cybersecurity Report, manufacturers are responding by deploying AI-driven detection systems alongside traditional security measures. The research highlights a shift towards intelligent security platforms that can identify anomalous behaviour in industrial control systems before threats escalate into production-halting incidents.

"The seventh instalment of the Fortinet State of Operational Technology and Cybersecurity Report shows that organisations are taking OT security more seriously," says Nirav Shah, Senior Vice President, Products and Solutions at Fortinet. "We see this trend reflected in a notable increase in the assignment of responsibility for OT risk to the C-suite, alongside an uptick in organisations self-reporting increased rates of OT security maturity."

Executive oversight drives security transformation

More than half of organisations now report that the Chief Information Security Officer (CISO) or Chief Security Officer (CSO) holds direct responsibility for OT security – a substantial increase from just 16% in 2022. When accounting for all C-suite roles involved in OT oversight, that figure reaches 95%.

This elevation of responsibility reflects how operational technology has evolved into a strategic risk domain. Connected devices and industrial control systems have become integral to digital transformation ambitions, requiring executive-level attention and resource allocation.

"Alongside these trends, we're seeing a decrease in the impact of intrusions in organisations that prioritise OT security," Nirav says.

"Everyone from the C-suite on down needs to commit to protecting sensitive OT systems and allocating the necessary resources to secure their critical operations."

AI-powered monitoring tackles industrial threats

The manufacturing sector remains the most targeted industry for cyber attacks, accounting for roughly a quarter of all global incidents. Statista reports that manufacturing faced 638 cyber attacks in 2023, with phishing attacks averaging 1.65 per user in the sector during 2024.

Threat actors increasingly deploy ransomware and wiper malware such as Ekans or Industroyer2 to cripple industrial operations. These attacks exploit the flattened architecture of many older OT environments, where limited segmentation allows malware to move laterally between IT and operational systems.

AI and ML are emerging as critical tools in this environment. AI-driven anomaly detection systems can identify irregular patterns in industrial protocols and controller behaviour that human analysts might miss.

Fortinet's research shows organisations with higher OT security maturity levels, including those implementing AI-powered monitoring, experience fewer operational outages and revenue impacts, down from 52% to 42% year-on-year.

Manufacturers implementing cyber hygiene practices, user awareness programmes and threat intelligence have significantly reduced business email compromise incidents. Organisations consolidating vendors into integrated OT security platforms have seen up to a 93% reduction in cyber incidents compared to flat networks, with seven times improvements in triage and setup times.

Strategies for intelligent security

Fortinet contends that manufacturers can fortify OT against escalating IT-OT convergence threats using a series of proven strategies from the report:

• Segment critical systems: Isolate OT from corporate IT using ISA/IEC 62443 zones to prevent lateral movement. FortiGate Rugged Firewalls deliver resilient protection in harsh industrial environments.
• Patch strategically: Schedule updates during maintenance windows to secure legacy assets without disrupting production.
• Monitor in real time: Use AI-driven anomaly detection to catch protocol misuse and controller irregularities early. FortiNDR enhances visibility across OT networks.
• Strengthen governance: Align cybersecurity with safety, compliance and executive oversight to ensure accountability and investment.
• Unify IT and OT teams: Enable shared monitoring and faster response with platforms such as FortiSIEM.
• Train the workforce: Deliver OT-specific security training, supported by FortiGuard OT Threat Intelligence for ICS-focused insights.

Manufacturing's low downtime tolerance makes it an attractive target for cyber criminals seeking maximum impact. However, Fortinet's data demonstrates that proactive strategies incorporating AI-powered detection and integrated security platforms are proving effective.

As threats evolve alongside smart factory growth, the combination of executive buy-in and intelligent monitoring systems positions manufacturers to protect production, intellectual property and safety in increasingly connected industrial environments.