Building a Secure OT Infrastructure at a Greenfield Metals Facility
- GPA
- Dec 4
- 2 min read
A new metals facility in the Southeastern U.S. partnered with Global Process Automation (GPA) to implement an Operational Technology (OT) solution. With no existing infrastructure, GPA built the process network from the ground up. The system combined hardware, software, and network design to meet the site’s operational and security needs.
The Challenge
The main objective was to create a secure OT layer that would serve as the foundation for all process systems. Key challenges included:
Designing portions of the process network for GPA’s system and integrating with vendor networks
Integrating multiple vendor systems while maintaining security and performance
Ensuring compliance with licensing requirements for software components such as VMWare by Broadcom
Coordinating logistics and installation across vendors, stakeholders, and facility teams
Technical Scope
GPA’s team delivered a solution focused on securing and standardizing the site’s OT infrastructure. Key scope items included:
Virtualization Environment: Deployment of a hyperconverged VMware infrastructure hosting Windows VMs for core OT services
Backup and Recovery: Configuration of a site-level backup solution supporting data protection and restore operations
System Monitoring: Integration of multiple monitoring tools to track performance, uptime, and security status
Patch Management: Implementation of a centralized patch management process for consistent system updates
Security Framework: Deployment of global single sign-on (SSO), group-based permissions, and policy enforcement to control access and streamline user management
Execution Strategy
The project progressed through four key stages:
Design Phase: GPA collaborated with vendors and the client facility to finalize system specifications and integration points
Procurement & Logistics: Hardware was shipped to GPA for preassembly and configuration before delivery to the facility
Installation & Commissioning: GPA performed onsite integration, acceptance testing, and commissioning
Post-Installation Support: Remote technical support time was provided to ensure operational continuity
Results and Impact
The project delivered:
A fully operational OT security layer supporting the facility’s process systems
Implementation of a Security Framework with single sign-on (SSO), group-based permissions, and policy enforcement for secure user management
Improved troubleshooting and maintenance through integrated infrastructure monitoring
A scalable and secure foundation supporting future expansion and operational efficiency
Conclusion
Building a secure and reliable OT foundation is essential for any new industrial operation. This case study highlights how GPA helped a metals facility achieve that goal through a complete infrastructure deployment. The solution improved reliability and data protection while lowering operating costs. Its scalable design supports future digital initiatives and delivers measurable returns through greater efficiency and uptime. Completion on time and within budget reflects GPA’s commitment to precise execution and client success.
