Ep 59: From Plant Operator to OT Security: Stories of Failures and Breakthroughs

In this episode, host Aaron Crow dives deep into the intersection of IT and OT cybersecurity with special guest Gavin Dilworth—a plant operator turned automation engineer and cybersecurity expert. Listen in as Gavin shares his candid and often humorous journey from factory floors to global consulting, including how a workplace near-miss sparked his “lightbulb moment” about the similarities between health and safety and cybersecurity.

Aaron and Gavin discuss everything from operators’ creative workarounds on the plant floor, to the importance of trust and rapport between IT and OT teams, and why having hands-on experience is key to building effective cybersecurity programs in critical infrastructure environments.

You’ll also hear real-world stories of technology mishaps, the critical role of plant culture, and the practical challenges organizations face in securing legacy systems while keeping operations running.

If you want honest, relatable insights and actionable advice on bridging the IT-OT divide—and a few laughs along the way—this episode is for you.

Key Moments:

10:12 Operator Rounds and RFID Challenges

12:56 Operators' Ingenuity and Knowledge

21:29 IT vs. OT: Firmware Update Challenges

26:49 Understanding and Accepting Risk

28:12 Standards, Frameworks, and Continuity

33:08 High Voltage Safety Precautions

40:41 Bridging OT and IT Skills

43:46 Cybersecurity Cross-Training Surge

52:38 CISO Knowledge Gap in OT Security

54:32 "Experience: Essential for Understanding"

01:03:34 DCS System Configuration Challenges

01:06:52 Neglecting Redundancy Risks Operations

01:11:00 Optimizing Underutilized IT Resources

01:20:04 "Understanding Systems Before Advice"

01:22:06 Old Cables Remain Untouched

About the guest :

Gavin Dilworth’s career took an unconventional path. As a plant operator, he was tasked with keeping production running smoothly and monitoring sensor readings, both on the computer and around the factory. However, Gavin was never quite the model operator—rather than dutifully making rounds and comparing readings, he often found himself absorbed in books, dreaming of a future in IT. Though he laughs about being a “pretty terrible operator,” Gavin’s story reflects his early drive to pursue his true interests in technology, even when duty called elsewhere.

How to connect Gavin :

Linkedin : https://www.linkedin.com/in/gavin-dilworth/

Website: https://assessmentplus.co.nz/

Connect With Aaron Crow: