Why Manufacturing Companies Struggle With Unknown Devices on Their Networks

How Industrial Network Monitoring Services Prevent Downtime and Security Breaches Industrial organisations depend on continuous operations to remain productive, safe, and profitable. Manufacturing plants, utilities, transport networks, and critical infrastructure systems are designed to run around the clock with minimal interruption. As these environments become more connected, however, they also become more vulnerable to cyber threats that can disrupt operations without warning. One of the most effective ways to reduce this risk is through comprehensive industrial network monitoring. Rather than reacting to incidents after damage has occurred, monitoring services provide ongoing visibility into connected devices and network activity, allowing organisations to identify risks early and prevent small issues from escalating into major outages. Why Downtime Is So Costly in Industrial Environments In industrial settings, downtime can quickly translate into significant financial loss. Production delays, equipment damage, safety incidents, and service interruptions all carry immediate and long-term costs. For infrastructure operators, outages may affect entire communities and result in regulatory penalties or loss of public trust. Cyber incidents are an increasingly common cause of unplanned downtime. Unauthorised devices, compromised hardware, and unmanaged systems can disrupt operations silently until failures occur. Without continuous monitoring, these risks often go unnoticed until systems are already affected. The Limitations of Traditional Monitoring Tools Many organisations rely on basic network monitoring tools designed for office IT environments. While these tools may track servers and user devices, they often fail to provide meaningful visibility across industrial networks. Operational environments include specialised hardware, legacy equipment, and devices that communicate intermittently or use proprietary protocols. Traditional monitoring approaches also focus heavily on traffic patterns rather than device awareness. This makes it difficult to identify unknown hardware, rogue devices, or abnormal connections that could indicate security threats. As a result, industrial organisations may believe they are monitoring their networks while significant risks remain hidden. How Industrial Network Monitoring Improves Security Visibility Industrial network monitoring services are designed specifically for complex operational environments. They provide continuous insight into connected devices across both IT and OT networks, revealing unmanaged assets and unusual behaviour that traditional tools miss. By maintaining real-time visibility into network activity and hardware connections, organisations can quickly identify unauthorised devices, detect suspicious changes, and investigate potential threats before they cause disruption. This proactive awareness allows security teams to respond early and reduce the impact of cyber incidents. Preventing Breaches Before They Escalate Many industrial cyber incidents begin with small, seemingly insignificant issues such as an unknown device connecting to a network or a temporary maintenance tool left behind after servicing. Without monitoring, these situations may persist for weeks or months, giving attackers time to exploit vulnerabilities. Continuous network monitoring enables organisations to detect these early warning signs and take action immediately. By identifying risks at the moment they appear, organisations can prevent breaches from spreading, limit operational impact, and avoid costly recovery efforts. Supporting Compliance and Operational Stability Ongoing monitoring also supports regulatory and compliance requirements by maintaining accurate records of connected devices and network activity. This simplifies audits, improves reporting accuracy, and demonstrates strong control over industrial environments. At the same time, modern industrial monitoring approaches are designed to be non-intrusive, ensuring visibility is achieved without disrupting sensitive systems or impacting performance. This allows organisations to strengthen security while preserving the stability their operations depend on. Building Stronger Industrial Resilience Through Monitoring  Industrial network monitoring is no longer a luxury—it is a critical component of modern cybersecurity strategies. As industrial environments grow more connected and complex, continuous visibility is essential for protecting operations, reducing downtime, and preventing security breaches. Organisations that invest in proactive monitoring gain greater control over their networks, faster threat detection, and improved operational resilience. By understanding what is happening across industrial systems in real time, they can stay ahead of emerging threats and ensure the long-term security of critical operations.

The Real Cybersecurity Risks Facing Critical Infrastructure Operations Today  Critical infrastructure organisations support the systems that communities depend on every day. Power networks, transport systems, utilities, telecommunications, and industrial facilities operate continuously and at massive scale. As these environments become more connected and digitally managed, they also become increasingly exposed to cyber threats. While many operators invest heavily in cybersecurity tools, significant risks continue to grow beneath the surface — often unnoticed until disruption occurs. The challenge is not simply defending against external attacks. It is maintaining visibility, control, and security across complex networks filled with industrial equipment, legacy systems, and constantly changing hardware. Why Infrastructure Networks Are Especially Vulnerable Infrastructure environments differ from traditional corporate networks in both scale and complexity. Devices are spread across large geographic areas, remote sites, and field locations. Many systems were installed years ago and were never designed with modern cybersecurity in mind. These environments often contain thousands of sensors, controllers, communication devices, and specialised equipment operating continuously. As connectivity increases, new devices are added to improve monitoring, efficiency, and automation. Over time, maintaining a complete understanding of what is connected becomes increasingly difficult. Unknown and unmanaged devices accumulate quietly, creating blind spots that attackers can exploit. Without clear visibility, infrastructure operators are left with incomplete security coverage across critical systems. The Hidden Dangers of Unmanaged Hardware Unmanaged devices represent one of the most significant risks in infrastructure cybersecurity. These devices may include field equipment, replacement components, temporary maintenance tools, or legacy systems that no longer integrate with modern monitoring platforms. Because they are not properly tracked or secured, they often run outdated software or lack basic security controls. Attackers actively target these weaknesses. Once compromised, unmanaged hardware can provide persistent access to operational networks, enabling data manipulation, service disruption, or lateral movement across systems. In environments where availability and reliability are essential, even minor compromises can lead to widespread outages and serious safety concerns. Why Traditional Security Tools Miss Infrastructure Threats Many cybersecurity solutions are built for office IT environments rather than industrial operations. They rely on software agents, frequent scanning, and network traffic analysis to identify threats. In infrastructure environments, these techniques are often ineffective or unsafe. Sensitive systems may not tolerate scanning, and many devices cannot support agents at all. As a result, large portions of infrastructure networks remain invisible from a security perspective. Operators may believe systems are protected while unknown hardware continues to operate unchecked. This gap between perceived security and actual visibility is where many major incidents begin. How Lack of Visibility Increases Operational and Financial Risk When infrastructure organisations lack clear insight into connected devices, risk grows across multiple dimensions. Cyber incidents become harder to detect, response times increase, and recovery becomes more expensive. Outages can disrupt essential services, damage public trust, and lead to regulatory scrutiny. In addition, compliance requirements often depend on accurate asset inventories and continuous monitoring. Without reliable visibility, organisations struggle to demonstrate control over their environments, increasing audit risk and administrative burden. Strengthening Infrastructure Security Through Device Awareness Improving cybersecurity in infrastructure environments starts with understanding what is connected. Device visibility services provide continuous insight into every asset across operational networks, including unmanaged and legacy hardware. By identifying devices based on physical characteristics rather than software behaviour alone, these services uncover blind spots that traditional tools miss. With full visibility, infrastructure operators can detect unauthorised devices in real time, enforce security policies more effectively, and reduce exposure to hidden threats. This proactive approach allows organisations to protect critical systems without disrupting operations or introducing intrusive controls. Building Resilient Infrastructure for the Future As infrastructure networks continue to evolve, cybersecurity strategies must evolve with them. Relying solely on traditional tools designed for corporate IT environments is no longer sufficient. Visibility at the device level is essential for managing risk, supporting compliance, and maintaining operational continuity. Organisations that invest in understanding their hardware environments gain stronger security foundations, faster incident response, and greater resilience against emerging threats. In today’s connected world, knowing what is on your network is not just good practice — it is a critical requirement for protecting the systems that keep society running.

How Device Visibility Services Help Industrial Networks Reduce Cyber Risk Industrial organisations are increasingly reliant on connected systems to keep operations running efficiently. From manufacturing plants to infrastructure networks, hundreds or even thousands of devices now communicate across operational environments every day. While this connectivity delivers productivity and insight, it also introduces a major cybersecurity challenge: many organisations no longer have a clear understanding of what is actually connected to their networks. Without accurate visibility into devices and assets, cyber risk grows silently in the background. The Growing Problem of Unknown Devices in Industrial Environments Industrial networks often contain a mix of modern systems, legacy equipment, sensors, controllers, and third-party devices. Over time, new hardware is added during upgrades, maintenance work, and operational expansions. In many cases, these devices are introduced without proper documentation or ongoing monitoring. As a result, organisations gradually lose track of what assets exist within their environments. Unknown and unmanaged devices create serious security blind spots. They may lack proper security controls, run outdated firmware, or provide unauthorised access points into critical systems. Because traditional cybersecurity tools are often designed for office IT environments rather than industrial networks, these devices frequently go unnoticed. Attackers actively look for these blind spots, knowing they provide easy entry points into otherwise well-protected environments. Why Traditional Security Tools Struggle With Industrial Networks Most conventional cybersecurity solutions rely on software agents, network scanning, or traffic analysis to identify devices and detect threats. While these approaches can be effective in corporate IT settings, they are far less reliable in industrial environments. Many industrial systems cannot support agents, and active scanning may disrupt sensitive equipment or operational processes. In addition, industrial devices often communicate using specialised protocols or remain inactive for long periods, making them difficult to detect using traditional monitoring tools. This results in incomplete asset inventories and a false sense of security. Organisations may believe their networks are protected while critical hardware remains unmanaged and invisible. What Device Visibility Services Actually Deliver Device visibility services focus on identifying every connected asset across industrial environments, including devices that traditional tools cannot see. Instead of relying solely on software information, these services recognise hardware based on its physical characteristics and connection behaviour. This provides a complete, accurate picture of what is connected across both IT and operational networks. With full device visibility, organisations can continuously track assets, detect unauthorised hardware in real time, and maintain reliable inventories without disrupting operations. This foundation of awareness allows security teams to make informed decisions, prioritise risks, and respond quickly when suspicious devices appear. Reducing Cyber Risk Through Better Asset Awareness When organisations know exactly what devices exist on their networks, they dramatically reduce the number of opportunities attackers can exploit. Unmanaged and unknown devices can be identified and secured, removed, or restricted before they become entry points for breaches. Improved visibility also supports stronger access control, enabling organisations to ensure that only approved hardware connects to critical systems. This approach aligns naturally with modern security strategies such as zero-trust principles, where trust is continuously verified rather than assumed. Over time, this leads to fewer incidents, faster detection of threats, and lower operational risk. Supporting Compliance and Operational Resilience Accurate device inventories are a core requirement for many cybersecurity and regulatory standards. By maintaining real-time visibility into connected assets, organisations can simplify audits, improve reporting accuracy, and demonstrate stronger control over their environments. This reduces administrative burden while improving overall security posture. Beyond compliance, device visibility strengthens operational resilience. When security teams understand their environments fully, they can respond to incidents more effectively, minimise downtime, and prevent small issues from escalating into major disruptions. Building a Safer Industrial Network With Device Visibility  As industrial environments continue to grow in complexity, relying on outdated asset tracking methods and IT-centric security tools is no longer sufficient. Device visibility services provide the clarity needed to secure modern networks, reduce cyber risk, and protect critical operations without interfering with daily activities. Organisations that invest in understanding what is truly connected to their networks gain a powerful advantage: fewer blind spots, stronger security controls, and greater confidence in their ability to protect essential systems. In today’s threat landscape, visibility is not just helpful — it is the foundation of effective industrial cybersecurity.

How Manufacturing and Infrastructure Organisations Can Reduce Cyber Risk Without Disrupting Operations Manufacturing and infrastructure organisations operate in environments where stability, safety, and uptime are critical. While cyber threats continue to grow in sophistication and frequency, many organisations remain cautious about introducing new security measures into operational environments. The concern is understandable: any disruption to production systems, control networks, or critical services can result in significant financial loss, safety risks, and reputational damage. However, avoiding security improvements altogether creates an equally serious risk, leaving systems exposed to threats that operate quietly and persistently. Why Uptime Is the Highest Priority in Industrial Environments In industrial settings, uptime is not simply a performance metric—it is a fundamental requirement. Manufacturing plants rely on tightly coordinated processes where delays or interruptions can cascade across production lines. Infrastructure operators manage systems that provide essential services such as power, water, transport, and communications, where outages can affect entire communities. Because of this, operational technology environments are designed to prioritise predictability and stability over flexibility. Changes are carefully planned, tested, and approved, and unexpected behaviour is treated as a serious incident. Cybersecurity solutions that introduce uncertainty, increase latency, or modify system behaviour are therefore viewed as potential threats rather than safeguards. This mindset, while necessary for safe operations, makes it difficult to adopt traditional security tools without compromising operational goals. The Risks of Intrusive Cybersecurity Approaches Many conventional cybersecurity tools depend on active scanning, frequent updates, or software agents installed directly on endpoints. In IT environments, these practices are standard and generally well tolerated. In industrial environments, however, they can introduce unacceptable risk. Legacy devices may not support agents, scanning can overload fragile systems, and unplanned network traffic can interfere with time-sensitive communications. As a result, organisations often restrict or disable security controls in operational environments. While this reduces the risk of immediate disruption, it also creates long-term vulnerabilities. Systems may appear stable while remaining completely unmonitored from a security perspective. Over time, this approach increases exposure to threats that exploit the absence of visibility rather than weaknesses in software. How Threats Exploit Operational Blind Spots Attackers are increasingly targeting industrial environments precisely because of these constraints. Hardware-based threats are particularly effective, as they do not rely on exploiting software vulnerabilities or triggering suspicious network activity. Malicious USB devices, compromised field equipment, or altered replacement components can be introduced during routine activities such as maintenance, upgrades, or supplier deliveries. Once connected, these devices may operate silently for extended periods, collecting data, manipulating processes, or maintaining persistent access. Because they function below the software layer, they often bypass traditional security controls entirely. In environments where physical access is distributed and third-party involvement is common, these threats can remain undetected while organisations focus on maintaining operational continuity. Gaining Visibility Without Disruption To reduce cyber risk without compromising uptime, industrial organisations need visibility solutions that are designed specifically for sensitive environments. Rather than relying on intrusive techniques, security controls must be passive, non-disruptive, and compatible with legacy systems. Hardware-level visibility meets these requirements by identifying devices based on their physical characteristics instead of software behaviour. Passive monitoring allows organisations to gain insight into connected devices without generating additional traffic, installing agents, or altering system configurations. This makes it possible to detect unmanaged, unauthorised, or rogue hardware without affecting performance or stability. By focusing on observation rather than interaction, organisations can achieve visibility while preserving operational integrity. Strengthening Security While Preserving Operational Stability When organisations gain accurate visibility into their hardware environments, they can make informed security decisions without introducing unnecessary risk. Hardware-centric visibility enables teams to build reliable asset inventories, understand normal device behaviour, and identify anomalies early. This approach supports proactive risk management rather than reactive incident response. Importantly, improved visibility does not require changes to existing workflows or operational processes. Security teams can monitor environments continuously while operations teams maintain control over system changes. This alignment between security and operations reduces friction, improves collaboration, and enables sustainable security improvements over time. Building a Sustainable Security Strategy for Industrial Operations Reducing cyber risk in manufacturing and infrastructure environments does not require choosing between protection and performance. By adopting non-intrusive, hardware-centric security approaches, organisations can address modern threats while preserving the stability their operations depend on. As industrial systems continue to evolve and connectivity increases, the ability to gain visibility without disruption will become a defining factor in effective cybersecurity strategies. Organisations that invest in this approach are better positioned to protect critical systems, meet compliance requirements, and maintain long-term operational resilience in an increasingly complex threat landscape.

Hardware Visibility: The Missing Layer in Industrial Cybersecurity Industrial organisations across manufacturing and infrastructure sectors are investing heavily in cybersecurity, yet many still struggle to prevent incidents that originate deep within their operational environments. Firewalls, endpoint protection, and network monitoring tools are widely deployed, but breaches continue to occur. The root cause is often not a lack of security tools, but a lack of visibility at the most fundamental level. Without clear insight into the physical devices connected to industrial networks, even the most advanced cybersecurity strategies remain incomplete. Why Visibility Is the Foundation of Industrial Security Effective cybersecurity starts with knowing what needs to be protected. In industrial environments, this is far more complex than in traditional IT networks. Manufacturing plants, utilities, and infrastructure operators rely on a diverse range of hardware including PLCs, sensors, controllers, gateways, and specialised field equipment. Many of these devices operate continuously, use proprietary protocols, or lack modern management interfaces. Traditional asset discovery tools depend on software agents, active scans, or network behaviour to identify devices. In industrial environments, these methods provide an incomplete picture and often miss unmanaged or legacy hardware entirely. When organisations do not have a reliable inventory of connected devices, they are unable to accurately assess risk, enforce security policies, or respond effectively to incidents. The Limitations of Software-Centric Security Models Most cybersecurity frameworks and tools are built around software identity. Devices are trusted based on IP addresses, MAC addresses, certificates, or installed agents. While this approach works reasonably well in IT environments, it breaks down in industrial settings where devices may share identifiers, change configurations, or operate without standard operating systems. Software-centric security models also struggle to detect devices that intentionally attempt to evade detection. Rogue hardware, spoofed devices, and malicious peripherals can impersonate trusted systems at the network level. Because traditional tools do not validate the physical characteristics of a device, these threats can remain hidden while maintaining apparent compliance with access controls. Hardware-Based Threats in Industrial Environments Hardware-based threats are particularly dangerous in industrial cybersecurity because they operate below the software layer. Malicious USB devices, compromised replacement components, and implanted hardware can introduce persistent access points or manipulate operational data without triggering conventional security alerts. In manufacturing and infrastructure environments, physical access is often distributed across large sites, remote facilities, and third-party contractors. This increases the likelihood that unauthorised or compromised hardware can be introduced during routine maintenance or upgrades. Without hardware visibility, these devices may remain connected indefinitely, creating long-term risk to operations, safety, and intellectual property. Why Industrial Environments Require a Different Approach Industrial operations place strict constraints on cybersecurity controls. Active scanning, frequent updates, and intrusive monitoring can disrupt processes, degrade performance, or create safety hazards. As a result, many organisations limit security activity in OT environments, accepting reduced visibility in exchange for operational stability. This trade-off is no longer sustainable. As industrial systems become more connected and threats more sophisticated, organisations need a way to gain visibility without disrupting operations. Hardware visibility provides this capability by passively identifying devices based on their physical attributes rather than relying on software interactions. How Hardware Visibility Strengthens Zero Trust and Compliance Zero trust principles require continuous verification of both users and devices. In industrial environments, enforcing zero trust without hardware visibility is ineffective. Organisations may validate credentials while unknowingly granting access to unauthorised or compromised hardware. Hardware visibility enables industrial operators to enforce trust at the device level, ensuring that only known and approved hardware can connect to critical networks. This capability also supports compliance with frameworks such as the NIST Cybersecurity Framework and CIS Controls, which require accurate asset inventories and continuous monitoring. By maintaining a real-time understanding of connected devices, organisations can reduce audit risk and improve regulatory readiness. Building Resilient Industrial Security with Hardware Visibility Industrial cybersecurity cannot rely solely on software-based controls. To protect complex manufacturing and infrastructure environments, organisations must address risk at the physical layer. Hardware visibility provides the missing foundation by revealing every connected device, including those that traditional tools cannot see. By adopting a hardware-centric approach, industrial organisations can reduce cyber risk, improve operational resilience, and maintain visibility without disrupting critical systems. As industrial networks continue to evolve, hardware visibility is no longer an optional enhancement—it is a core requirement for effective, long-term cybersecurity.

Why Infrastructure Cybersecurity Fails Without Hardware Visibility Critical infrastructure organisations operate some of the most complex and high-risk environments in the world. Energy networks, transport systems, utilities, telecommunications, and national infrastructure rely on highly connected operational technology environments where uptime, safety, and reliability are non-negotiable. Despite this, many infrastructure operators continue to rely on traditional cybersecurity tools that were designed for corporate IT networks, not mission-critical systems. This disconnect creates hidden risks that threaten both operational continuity and public trust. The Unique Cybersecurity Challenges of Infrastructure Environments Infrastructure networks are fundamentally different from standard enterprise environments. They often span vast geographic areas, incorporate legacy systems, and support a wide range of devices including SCADA controllers, sensors, field equipment, and industrial gateways. Many of these devices were never designed with modern cybersecurity in mind and cannot support agents, software updates, or active scanning. As infrastructure systems become more interconnected, the number of devices connected to operational networks continues to grow. Without complete visibility, organisations struggle to maintain an accurate understanding of what hardware is present, where it is located, and whether it should be trusted. This lack of awareness creates opportunities for unmanaged, unauthorised, or compromised devices to operate unnoticed within critical systems. Why Traditional Security Tools Miss Infrastructure Risks Traditional cybersecurity platforms focus on software identity, network traffic patterns, and user authentication. While these controls are valuable, they provide limited protection in infrastructure environments where many devices do not behave like standard IT endpoints. Industrial hardware often communicates intermittently, uses proprietary protocols, or remains silent for long periods, making detection based on traffic analysis unreliable. In addition, many infrastructure organisations restrict active scanning to avoid performance degradation or system instability. This necessary caution means that large portions of the environment remain effectively invisible to security teams. As a result, hardware-based threats can persist undetected, bypassing controls that were never designed to verify the physical identity of connected devices. Hardware-Based Threats in Critical Infrastructure Hardware-based attacks represent a growing threat to infrastructure operators. Rogue field devices, compromised replacement components, and malicious peripherals can be introduced during maintenance, upgrades, or third-party interventions. Once connected, these devices may provide persistent access, manipulate operational data, or interfere with system behaviour. Unlike software-based attacks, hardware threats operate below the operating system level. They can evade endpoint detection, antivirus, and intrusion prevention tools entirely. In infrastructure environments where physical access is often distributed and difficult to monitor, these risks are particularly challenging to detect and control using traditional cybersecurity methods. Compliance and Regulatory Pressure on Infrastructure Operators Infrastructure organisations face increasing regulatory scrutiny and compliance obligations. Frameworks such as the NIST Cybersecurity Framework, CIS Controls, and sector-specific regulations require operators to identify, manage, and monitor all connected assets. Accurate asset inventories are a foundational requirement for demonstrating compliance and managing risk. Without reliable hardware visibility, compliance efforts become reactive and manual. Asset records quickly become outdated as devices are added, replaced, or relocated. During audits or incident investigations, the inability to prove control over connected hardware can lead to regulatory penalties, operational delays, and reputational damage. Why Hardware Visibility Is Essential for Infrastructure Security To secure infrastructure environments effectively, organisations must address cybersecurity at the physical layer. Hardware visibility enables operators to identify every connected device based on its physical characteristics rather than relying solely on software identifiers or network behaviour. This approach provides a complete and accurate inventory across both IT and OT environments. By establishing hardware visibility, infrastructure operators can detect rogue or unauthorised devices in real time, enforce device-level trust policies, and maintain continuous awareness without disrupting operations. Passive monitoring techniques allow visibility to be gained safely, even in environments where uptime and stability are critical. Strengthening Infrastructure Resilience Through Hardware-Centric Security Infrastructure security is ultimately about resilience. The ability to detect threats early, respond effectively, and maintain safe, reliable operations depends on understanding exactly what hardware is connected to critical systems. Hardware-centric security provides the foundation needed to reduce risk, support compliance, and protect essential services. As infrastructure networks continue to evolve, relying solely on traditional cybersecurity tools is no longer sufficient. Organisations that invest in hardware visibility gain the insight needed to secure complex environments, protect against emerging threats, and ensure the continuity of services that communities depend on every day.

Why Traditional Cybersecurity Fails in Manufacturing OT Environments Manufacturing organisations are facing unprecedented cyber risk as operational technology environments become more connected and digitally integrated. While this connectivity improves efficiency and visibility, it also exposes production systems to threats that traditional cybersecurity tools are not equipped to handle. Many manufacturers continue to rely on IT-focused security solutions, assuming they can be extended to OT environments. In practice, this assumption creates critical security gaps that attackers are increasingly able to exploit. The Visibility Problem in Manufacturing Networks A fundamental weakness in manufacturing cybersecurity is the lack of accurate visibility into connected devices. OT environments are made up of a diverse mix of equipment, including legacy machines, PLCs, sensors, controllers, and specialised industrial systems. Many of these assets were deployed years or even decades ago, long before modern cybersecurity considerations existed. As a result, they often cannot support agents, active scans, or modern management protocols. Without reliable visibility, manufacturers are unable to answer basic but critical questions: what devices are connected, where they are located, who owns them, and whether they are authorised. Traditional security tools depend heavily on IP addresses, software identifiers, or user credentials, which provide an incomplete picture in OT environments. This lack of clarity creates blind spots where unmanaged or unauthorised hardware can operate undetected. IT and OT Convergence Increases Hardware Risk As IT and OT networks converge, the attack surface in manufacturing environments expands significantly. Remote access for engineers, cloud-connected monitoring systems, and third-party maintenance tools introduce new entry points into production networks. While these connections are often necessary for operational efficiency, they also increase the risk of unauthorised hardware being introduced into sensitive environments. Devices such as laptops, diagnostic tools, USB drives, and replacement components are frequently connected during maintenance or upgrades. In many cases, these devices are trusted by default, with little or no verification of their origin or integrity. Traditional cybersecurity controls focus on authenticating users, not the physical devices themselves. This creates an opportunity for rogue or spoofed hardware to gain access to critical systems without triggering alerts. Why Agent-Based Security Does Not Work in OT Most conventional cybersecurity solutions rely on agents, active scanning, or continuous interrogation of systems to detect threats. While effective in corporate IT environments, these techniques are often unsuitable for manufacturing operations. OT systems are highly sensitive to performance changes, network latency, and unexpected traffic. Even minor disruptions can halt production lines, damage equipment, or compromise safety. Because of these risks, many manufacturers limit or completely disable active security controls in OT environments. This trade-off between security and uptime leaves critical systems exposed to threats that operate silently at the hardware level. The result is a security posture that appears compliant on paper but lacks real-world protection against physical-layer attacks. The Growing Threat of Hardware-Based Attacks Hardware-based threats represent one of the most significant and least understood risks in manufacturing cybersecurity. Malicious USB devices, compromised replacement parts, and implanted hardware can bypass software-based controls entirely. Once connected, these devices can intercept communications, manipulate processes, or provide persistent access to attackers. Unlike malware, hardware threats do not rely on exploiting operating systems or applications. They operate below the software layer, making them invisible to traditional endpoint detection, antivirus, and network monitoring tools. In manufacturing environments where physical access is often easier to obtain, these threats pose a serious risk to intellectual property, production integrity, and operational continuity. Compliance Challenges Without Accurate Asset Inventories Manufacturers are increasingly required to comply with cybersecurity frameworks and standards such as the NIST Cybersecurity Framework and CIS Controls. These frameworks place strong emphasis on asset identification, inventory management, and continuous monitoring. Without accurate visibility into hardware assets, compliance becomes a manual and error-prone process. Many organisations rely on spreadsheets or outdated CMDBs that quickly fall out of sync with reality. Devices are added, removed, or replaced without proper documentation, increasing audit risk and operational overhead. In the event of an incident or regulatory review, the inability to demonstrate control over connected assets can have serious financial and reputational consequences. Why Hardware Visibility Is the Foundation of OT Security To effectively secure manufacturing OT environments, organisations need to move beyond traditional cybersecurity approaches and address risk at the physical layer. Hardware visibility provides a reliable foundation by identifying devices based on their physical characteristics rather than software attributes. This approach enables manufacturers to see every connected device, including those that are unmanaged, legacy, or intentionally hidden. By establishing accurate hardware visibility, manufacturers can enforce zero-trust principles for devices, validate third-party equipment, and detect rogue or spoofed hardware without disrupting operations. Passive, non-intrusive monitoring allows security teams to gain insight without impacting production systems or introducing additional risk. Building Resilient Manufacturing Operations Through Hardware-Centric Security Manufacturers that adopt a hardware-centric approach to cybersecurity are better positioned to protect their operations in an increasingly complex threat landscape. By understanding exactly what is connected to their networks, they can reduce cyber risk, safeguard intellectual property, and maintain operational uptime. As manufacturing continues to modernise, traditional cybersecurity tools alone are no longer sufficient. Visibility at the hardware layer is essential for securing OT environments, meeting compliance requirements, and ensuring long-term resilience. Organisations that address these challenges proactively will be better equipped to protect their production environments today and adapt to emerging threats in the future.

Introduction: Risk Scoring Needs a Reality Check Cybersecurity teams depend on risk scoring to decide what to fix, where to invest, and how to prioritise threats. Yet most risk scores are built on one critical assumption — that the underlying device reporting the data is trustworthy. In a world of spoofed peripherals, tampered components, and unmanaged IoT devices, that assumption often fails. This is why hardware-level trust is becoming essential. Sepio’s Hardware DNA technology introduces a new model of risk scoring that measures devices at the physical layer, not just the software layer, giving organisations a more accurate understanding of what they’re actually securing. The Blind Spot in Traditional Cyber Risk Scores Most risk scores focus on software vulnerabilities, patch status, access rights, user behaviour, and network exposure. But none of these metrics matter if the device providing them isn’t genuine. A compromised device can appear completely legitimate while silently operating outside policy — meaning traditional risk scoring starts from the wrong baseline. This is the core flaw: if you can’t trust the device, you can’t trust the score. In modern environments, attackers know this. They exploit hardware that can disguise itself, bypass agents, or blend in using spoofed identifiers. As a result, risk scoring built solely on software data gives a false sense of security. Why Hardware DNA Changes Everything Sepio’s Hardware DNA fingerprinting identifies devices based on their physical and electrical characteristics — attributes that cannot be faked or manipulated. This allows security teams to determine, with certainty, whether a device is authentic, compromised, or completely unknown. Instead of relying on what the device claims to be, Hardware DNA reveals what the device actually is. This provides a level of assurance traditional tools simply cannot match. From the moment a device connects, Sepio generates a trust score based on its identity, behaviour, and deviation from known baselines. This becomes the foundation of a much more accurate risk scoring model — one grounded in physical truth, not software assumptions. A Better Foundation for Zero Trust Zero Trust is built on the principle of continuous verification, but most Zero Trust strategies only verify users, network requests, and application access. They rarely validate the physical device itself. This creates an obvious gap: if a rogue device impersonates a trusted endpoint, it can slip into the network long before any Zero Trust control activates. Hardware DNA closes that gap by ensuring the device is legitimate before it’s allowed to participate in any authentication or communication process. With hardware-level trust in place, Zero Trust becomes more than a concept — it becomes enforceable. Improving Compliance and Governance Regulatory frameworks increasingly expect organisations to maintain accurate, real-time asset inventories. But verifying that those assets are genuine is nearly impossible without hardware visibility. Hardware DNA gives compliance teams something they’ve never had before: evidence that the devices in their inventory are authentic, unchanged, and operating as expected. This strengthens alignment with frameworks such as NIST CSF, CIS Controls, and CISA BOD 23-01, all of which depend on accurate asset discovery and verification. Why CISOs Are Turning to Hardware-Level Risk Metrics CISOs are adopting Hardware DNA because it enhances decisions across the entire security programme. With genuine device verification, incident response becomes faster, asset management becomes more reliable, and the overall attack surface becomes smaller. Security tools also become more effective because they’re finally working with trustworthy data. When the hardware is reliable, every other control becomes more dependable. Zerium’s Role: Turning Hardware DNA Into a Security Capability The technology is powerful, but meaningful change requires strategy and integration. As the UK’s authorised partner for Sepio, Zerium helps organisations embed hardware trust into their risk frameworks, Zero Trust initiatives, asset inventories, and operational security processes. Zerium ensures that hardware-level visibility isn’t just switched on — it’s aligned with policy, governance, and the wider cybersecurity strategy, delivering long-term value rather than a one-off deployment. Conclusion: Trust Begins at the Physical Layer Cyber risk scoring only works when the underlying device data is reliable. By introducing Hardware DNA, Sepio creates a new standard for measuring trust — one that starts at the physical foundation of every digital environment. With Zerium’s expertise supporting implementation and strategy, organisations gain a clearer, more accurate picture of risk and a stronger basis for compliance, Zero Trust, and day-to-day security decisions. In modern cybersecurity, trust must be measured — and it must begin with the hardware itself.

Introd uction: Shadow IT Was Just the Beginning For years, CISOs have battled Shadow IT — the apps, cloud services, and software tools users bring into the organisation without approval. Most security teams now have processes to monitor, restrict, or integrate those unauthorised services. But a new, far more dangerous threat is emerging: Shadow Hardware. These are the physical devices — many of them small, discreet, or seemingly harmless — that enter your environment without approval, monitoring, or security validation. They connect instantly, operate silently, and pose a level of risk that Shadow IT never could. Unmanaged and unseen hardware isn’t just an operational problem. It’s becoming a major compliance challenge, particularly for frameworks that assume complete asset visibility. CISOs are now realising that if Shadow IT was a storm, Shadow Hardware is the hurricane behind it. What Exactly Is Shadow Hardware? Shadow Hardware refers to any physical device connected to your environment without explicit approval or visibility. These devices often enter networks unnoticed because traditional tools rely on agent installations, software identifiers, or manual onboarding processes. Shadow Hardware includes: USB devices that impersonate keyboards or network adapters IoT sensors and smart devices deployed without IT oversight Personal laptops, tablets, or phones connected to internal networks Rogue access points or Wi-Fi repeaters Unauthorised peripherals such as cameras, dongles, or storage devices Devices intentionally disguised or spoofed to blend in These assets create a blind spot that software-based tools simply cannot close. Shadow Hardware thrives in environments where users can connect any device to a port, plug into a network, or join a wireless segment with ease. Why Shadow Hardware Is a Bigger Problem Than Shadow IT Shadow IT creates data and compliance challenges, but Shadow Hardware creates something far more serious: direct network risk. Once a physical device connects, it’s inside the boundary. It doesn’t need credentials, It doesn’t need permission, It just needs a port. This makes Shadow Hardware particularly dangerous because: Many devices can spoof trusted identities, making them appear legitimate. A compromised device can bypass access controls before software tools even detect it. Rogue hardware can exfiltrate data, create backdoors, or manipulate network flows. Insider threats can introduce hardware tools without leaving a digital trace. IoT devices often run outdated firmware and default credentials. Shadow Hardware turns the physical layer into a hidden attack surface — one that traditional cybersecurity stacks were never built to see. Why Frameworks Are Tightening Requirements Around Hardware Visibility Frameworks like NIST CSF, CIS Controls, and CISA BOD 23-01 increasingly emphasise complete asset visibility — including physical devices. They assume organisations can confidently answer questions like: What devices are connected right now? Who authorised them? Are they genuine? Do they comply with policy? Are they managed, unmanaged, or rogue? For many organisations, the answer is: “We don’t know.” This uncertainty is exactly what regulators are trying to eliminate. Compliance frameworks expect real-time accuracy, not estimates. Shadow Hardware makes compliance nearly impossible because it operates outside the systems designed to track assets. If you can’t see the device, you can’t secure it — and you certainly can’t prove compliance. The Visibility Gap: Why Traditional Tools Can't Detect Shadow Hardware Most cybersecurity tools depend on software fingerprints. They identify assets through methods like agent installations, MAC addresses, vendor IDs, operating system reports and authenticated scans. But Shadow Hardware doesn’t have to follow these rules. A rogue USB can claim to be a keyboard. A malicious access point can spoof a trusted MAC address. A compromised device can masquerade as something benign. When tools rely on what a device claims to be, they become easy to fool. Shadow Hardware exploits this flaw by hiding in the gaps — between ports, between scans, and between layers of software visibility. This is why the physical layer has become the newest front in cybersecurity. And it’s where Sepio stands out. How Sepio Exposes Shadow Hardware Instantly Sepio’s Asset Risk Management (ARM) platform introduces a radically different approach to device visibility. Instead of relying on software identifiers or installed agents, it identifies devices using Hardware DNA — a fingerprint based on physical and electrical characteristics. This means that even if a device tries to disguise itself, Sepio sees its real identity. When Shadow Hardware connects, Sepio: Recognises the device instantly Detects whether it matches an approved profile Flags rogue or previously unseen devices Identifies spoofed peripherals Assigns a risk score based on behaviour and trust level Triggers enforcement actions automatically This closes the visibility gap completely. No Shadow Hardware can operate without immediate detection. Shadow Hardware and Compliance: The Coming Storm for CISOs Compliance is shifting from documentation to evidence. Regulators and auditors no longer accept theoretical asset inventories — they want real-time facts. Shadow Hardware disrupts compliance across multiple areas: NIST CSF: violates the Identify and Protect functions by introducing unverified assets. CIS Controls 1–2: breaks the requirement to inventory and control enterprise and software assets. CISA BOD 23-01: makes continuous asset discovery impossible. GDPR Article 32: undermines security of processing by enabling unauthorised data access. A single rogue device can invalidate your compliance posture — even if everything else is aligned. CISOs that mastered Shadow IT must now apply the same discipline, vigilance, and visibility to hardware. How Zerium Helps Organisations Eliminate Shadow Hardware Technology is only half the answer. To truly eliminate Shadow Hardware, organisations need strategy, policy, and operational implementation — all of which Zerium provides. As the UK’s authorised partner for Sepio, Zerium helps organisations: Establish hardware-layer Zero Trust policies Integrate Hardware DNA insights into compliance programmes Build processes to manage and verify all devices Detect, classify, and respond to rogue hardware activity Align with frameworks including NIST CSF, CIS Controls, and CISA directives Reduce risk in environments where unmanaged devices are common Zerium makes hardware visibility not just possible, but practical — and sustainable. Conclusion: Shadow Hardware Is the New Frontier — Visibility Is the New Requirement Shadow IT changed how CISOs think about applications. Shadow Hardware is about to change how they think about everything else. Devices that operate outside approval are no longer rare — they’re becoming the rule in hybrid workplaces, IoT-rich environments, and distributed networks. To meet modern compliance expectations and build a truly secure Zero Trust environment, CISOs must gain full, continuous visibility into the physical layer. With Sepio’s Hardware DNA technology and Zerium’s framework-aligned expertise , organisations can finally eliminate the blind spots Shadow Hardware depends on. Because in the modern enterprise, if you can’t see the device, you can’t trust it. And if you can’t trust it — you can’t secure it.