Honeywell Survey Finds 88% Overestimate OT Security Readiness
Most industrial leaders claim mature security, yet only a fifth have a full asset list. AI threats are rising while detection lags.
Key points
- 88% of leaders view their security as mature, but only 21% have a full asset inventory.
- Average downtime from major incidents is 16.2 hours, costing up to $500,000 per hour.
- 99% expect AI to affect security soon, yet only 23% use autonomous detection tools.
A new industry report highlights a stark disconnect between confidence and capability in critical infrastructure security. While most leaders believe their systems are robust, the data suggests they lack basic visibility into what is actually connected to their networks.
The survey, conducted by Honeywell Technologies and reported by VMblog, indicates that organizations are underestimating the complexity of their operational technology environments. This gap leaves many vulnerable to threats that can disrupt physical operations and safety.
Confidence masks a visibility gap
Of the more than 600 global leaders surveyed, 88% described their cybersecurity programs as mature. However, only 21% reported having a complete inventory of their operational technology assets. This means many organizations are managing security without a full map of their own digital and physical footprint.
The lack of integrated monitoring is widespread. Just one-third of organizations have fully integrated operational technology into a centralized security operations center. Even fewer, only 20%, continuously monitor connected devices like sensors and cameras, leaving significant blind spots in their defense.
Downtime costs escalate rapidly
When breaches occur, the financial impact is severe. The average downtime for the most significant incident was 16.2 hours, with losses reaching up to $500,000 per hour. These figures demonstrate that cyber incidents are no longer just IT problems but operational crises that directly hit the bottom line.
The energy and maritime sectors are particularly affected. Ninety-one percent of energy and utilities respondents reported a significant incident in the past year, while 87% of maritime leaders faced similar challenges. This high frequency of attacks underscores the urgency for better preparedness in these critical industries.
AI readiness lags behind threats
The threat landscape is evolving with the rise of artificial intelligence. Ninety-nine percent of respondents expect AI to impact operational technology security within the next three years. Despite this, only 23% are currently using autonomous or agentic tools for threat detection, creating a dangerous asymmetry.
Organizations with stronger visibility are four times better positioned to respond to incidents. The report concludes that resilience depends on extending security across every connected system, as the gap between perceived maturity and actual readiness poses a direct risk to business continuity and safety.
