“Every missed patch is a ticking vulnerability, just one exploit away from costing millions in downtime.”
Industrial control systems (ICS), OT networks, SCADA, PLCs, they are the backbone of modern infrastructure. Yet, when it comes to patches, many organizations treat them like a scheduling inconvenience. This is because of a lack of awareness of the impact of not patching. Delay too long, though, and what seemed like an innocuous firmware update becomes a gateway for disaster.
In this blog, we’ll explore why delaying patches is no longer optional, examine real-world statistics and incidents, highlight typical barriers, and show how OTNexus’s Patch Management module helps organizations stay ahead of the curve.
Why Patches Matter More Than Ever
- Exploiters Move Fast;
In 2025, data from IBM X-Force shows that of the vulnerabilities disclosed in H1 2025 that could impact OT, nearly half (49%) have a CVSS rating of High or Critical, and about 21% of the Critical ones already have publicly available exploit code. [IBM X-Force]. That means leaving known holes unpatched isn’t a theoretical risk, it’s a ticking time bomb.
- Physical Consequences & Financial Losses
When OT systems are breached, it isn’t just data at risk, physical operations are impacted. The IBM report noted that 15% of studied organizations experienced cybersecurity incidents affecting their OT environments; of those, nearly 25% reported that OT equipment or systems were damaged. The average cost? USD 4.56 million [IBM X-Force]. Manufacturing, utilities, energy and any environment where downtime or error can cascade are especially exposed.
- Patch Delay Is Commonplace
According to the TXOne 2024 Annual OT/ICS Cybersecurity Report, 85% of organizations do not conduct regular patching in OT. Most apply patches only quarterly or less often. Meanwhile, 37% of OT security incidents involved exploitation of vulnerabilities in software.
Real-World Case Studies
| Case | What Happened | Key Lesson |
|---|---|---|
| Schneider & GE Digital SCADA Vulnerabilities | The SCADA software used by many sites had high severity flaws. When disclosed, many users delayed patching due to concern over disruption or vendor compatibility. ats.ae | Timely vendor communication + testing environments are critical. Vendor delays and lack of patch validation can multiply risk. |
| “CrowdStrike Outage” from a Buggy Patch | In mid-2024 (approx.), CrowdStrike issued a patch to millions of client machines. The patch turned out to be faulty, causing system crashes (Blue Screens of Death) across many systems. Recovery took time and manual effort. Trustwave | Even vetted patches can have unintended consequences. That means having rollback plans, backup states, and testbeds is essential. |
| Waterfall’s 2024 Threat Report – Manufacturing Shutdowns | Over 500 sites across manufacturing, process, and critical infrastructure were impacted by cyber-attacks in 2023. More than half of those (54%) targeted manufacturing. Many incidents involved ransomware that exploited outdated or unpatched systems. Waterfall Security Solutions | Unpatched systems amplify ransomware risk. The lag between vulnerability disclosure and industrial patching is a window attackers are exploiting. |
Why Do Many OT Organizations Hesitate to Patch?
- Lack of Awareness of the Vulnerability That a Patch Addresses
Many teams simply aren’t aware what risk an unpatched vulnerability poses whether it could lead to safety hazards, process disruption, or regulatory fines. According to a Ponemon Institute survey, 62% of organizations were unaware that their systems were vulnerable before being breached due to a known patch-able weakness. [servicenow]
- Fear of Operational Disruption or Downtime
The systems often run continuously; even short downtimes can be very costly, both in safety and throughput. TXOne’s survey found that 47% of organizations cited concerns about disruption/downtime as a major barrier to patching. [TXOne 2024 Annual OT/ICS Cybersecurity Report]
- Lack of Expertise or Personnel
Nearly half (48%) said they don’t have enough specialist OT cybersecurity staff to evaluate, test, and deploy patches safely. [TXOne 2024 Annual OT/ICS Cybersecurity Report]
- Vendor Support Delays & Patch Testing
Some vendors are slow to release patches; others don’t support older equipment. Also, testing patches in an OT context (with all dependencies, safety interlocks etc.) is complex. In the TXOne survey, 43% mentioned lack of vendor support or testing capacity. [TXOne 2024 Annual OT/ICS Cybersecurity Report]
- Poor Asset Visibility / Outdated Inventory
You can’t patch what you can’t see. If you don’t have good data on what firmware versions, configurations, or devices are deployed, patching becomes risky. Legacy OT devices may not be properly inventoried or may even run unsupported firmware. (See the “Analysis of Publicly Accessible OT and Associated Risks” report showing many exposed devices with known critical vulnerabilities still unpatched years after disclosure. [arXiv]
What Helps: Best Practices & Mitigation Strategies
- Prioritize Based on Risk
Not all vulnerabilities are equal. Focus first on high/critical CVEs, systems with remote access, or safety-critical assets. Use vulnerability scoring + asset criticality to triage what must be patched fastest.
- Use Maintenance Windows / Planned Downtime
Many organizations schedule patching during periods of reduced load. While not always convenient, this reduces risk of unplanned outages. According to TXOne, nearly 60% apply patches during planned downtime. [SecurityWeek]
- Test Patches before Deployment & Ensure Roll Back
Establish small test-beds or isolated environments to validate patches for compatibility with OT devices, firmware, and safety interlocks ensuring rollback capability.
- Incremental / Phased Deployment
Apply patches in phases small number of devices → monitor → then wider rollout.
- Maintain Asset Visibility
Know what devices, firmware, OS versions, and configurations are in your OT estate. Use tools to track configuration drift.
- Vendor & Supply Chain Management
Ensure vendors provide patch documentation, SBOM (Software Bill of Materials), and support legacy gear. Include in contracts.
Enter OTNexus: How the Patch Management Module Helps You Stay Ahead
Here’s how OTNexus’s patch management module is designed to address the challenges above, helping industrial organizations patch quickly without breaking the plant:
| Capability | What It Does | Why It Matters |
|---|---|---|
| Comprehensive Asset Inventory + Firmware Version Tracking | Automatically discovers OT assets (PLCs, SCADA/HMI, sensors, controllers) and tracks firmware/OS/patch version. | Eliminate blind spots. You know exactly what is out of date or requires urgent attention including legacy devices. |
| Risk-Prioritization Dashboard | Combines CVE severity, exploit availability, asset criticality, remote exposure, safety risks, regulatory obligations. | Help you decide which patches to apply first, so you get maximum risk reduction per patch. |
| Testing & Roll-back Support | Supports staging environments (sandboxed / mirrored subsets), patch simulation, and automatic rollback mechanisms. | Reduce fear of disruption or unintended consequences. |
| Scheduling & Phased Deployment Tools | Plan patches during maintenance windows; roll out in phases; monitor success / failure metrics. | Enable smoother patch cycles, less risk, reduced impact during peak operations. |
| Vendor Patch Integration & SBOM Support | Maintains repository of vendor patches, tracks dependencies, shows whether vendors offer legacy support, provides SBOM info if available. | Speeds up response after vendor release; reduces “vendor support” bottleneck. |
| Audit Trails & Regulatory Compliance | Logs all patching decisions, tests, approvals, and deployments; maps to standards such as IEC 62443, NIST CSF, etc. | Makes it easier to satisfy auditors and regulations; evidence in case of incident. |
Putting It All Together: A Sample Patch Decision Workflow
Here’s how an ideal, low-risk yet fast patch loop might look using OTNexus:
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- Patch Release Notification → OEM releases a patch; OTNexus logs approval status.
- Validation & Risk Review → Security and engineering teams document patch testing and potential impacts in OTNexus
- Prioritization → Critical updates are scheduled first, while lower-risk patches are planned for maintenance windows.
- Installation Management → Patch deployments are tracked centrally within OTNexus, showing where and when patches were applied.
- Audit Trail → Every action is automatically recorded, ensuring you have compliance documentation ready for regulators or internal audits.
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Conclusion: Delay Isn’t an Option Anymore
In today’s OT threat landscape:
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- Attackers are exploiting Known vulnerabilities faster than ever.
- OT incidents cost millions in downtime, equipment damage, regulatory penalties.
- The barriers to patching fear, vendor delays, lack of visibility are real, but manageable.
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With OTNexus’s Patch Management module, patching becomes a structured, repeatable, and auditable process. Instead of reactive firefighting, you gain confidence, compliance, and continuity.
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