Cybersecurity in Manufacturing: Navigating the Digital Frontier in 2025

It’s 2025, and the manufacturing landscape has transformed dramatically. A glucometer manufacturing company operates 15 smart manufacturing units worldwide, seamlessly connected to a network of vendors and suppliers. However, one fateful day, a cyberattack on the test strip supplier sends shockwaves through the entire operation. The malicious code infiltrates the supplier’s system, causing a temporary production shutdown and attempting to replicate itself across all connected partners’ networks.

This scenario may sound fictional, but it reflects a growing reality. In fact, 79% of manufacturing houses believe that cyber risk poses a greater threat to smart factories than to their traditional counterparts. As manufacturers invest heavily in digitalization and embrace Industry 5.0, the vulnerabilities associated with increased connectivity are becoming alarmingly apparent.

In this article, we will delve into the multifaceted aspects of cybersecurity in manufacturing, exploring the challenges faced by the industry, the various types of risks, their repercussions, and effective strategies to bolster cybersecurity measures.

Why Does Manufacturing Remain One of the Most Cyber-Attacked Industries?

Manufacturing is a prime target for cybercriminals, with over 377 confirmed reports of ransomware and database leaks in the first half of 2024 alone. The primary reason for this vulnerability lies in the persistent gap between investments in cybersecurity for Operational Technology (OT) compared to Information Technology (IT). This disparity undermines the effectiveness of cybersecurity measures in the manufacturing sector, especially as the convergence of IT and OT becomes increasingly essential.

The technological landscape presents unique challenges. OT cybersecurity differs significantly from IT cybersecurity, as installing endpoint detection and response agents on Industrial Control Systems (ICS) or SCADA equipment is often impractical. Consequently, OT security relies heavily on monitoring network traffic, which poses both cost and technical challenges.

Moreover, the capital-intensive nature of manufacturing means that equipment is expected to last for years with limited software updates. This long technology lifecycle, combined with infrequent updates, increases the likelihood of unpatched vulnerabilities. Legacy equipment often requires additional logging and monitoring, further complicating the data infrastructure and exacerbating the cybersecurity challenges faced by manufacturers.

Types of Cybersecurity Risks in Manufacturing

The manufacturing sector faces a variety of cybersecurity risks that can disrupt production and lead to significant financial and reputational losses. Here are some of the most pressing threats:

1. Vulnerability Exploitation: Weak authentication protocols, insufficient encryption, outdated software, and unsecured network connections can open doors for unauthorized access, allowing intruders to control vital processes and sensitive data.

2. Hacking and Data Theft: The interconnected nature of smart factories creates entry points for hackers to infiltrate networks, steal confidential information, compromise intellectual property, and disrupt business operations.

3. Malware Attacks: Malware can infect systems, interfere with production processes, and cause extensive damage to both data and production lines.

4. Denial-of-Service Attacks: Such attacks can overwhelm factory systems with excessive traffic, rendering them unavailable and interrupting critical operations, leading to prolonged downtime and financial repercussions.

5. Man-in-the-Middle Attacks: In smart factories, where data flows continuously between devices and systems, these attacks can intercept communications, altering or stealing information and compromising data integrity and confidentiality.

Approaching Cybersecurity in the Manufacturing Industry

As the manufacturing sector embraces smart technologies, the need for robust cybersecurity measures has never been more critical. Here are key strategies to enhance cybersecurity in manufacturing:

1. Achieve Full Visibility Across Cyber-Physical Systems (CPS)

A comprehensive view of operational technology and cyber-physical systems, including IoT and IIoT devices, is essential for maintaining robust cybersecurity. Implementing a CPS protection platform with customizable discovery methods ensures that no part of the network is left unchecked, allowing for effective monitoring and security.

2. Integrate IT Tools and Workflows with CPS

Integrating IT tools and workflows with OT systems is crucial for bridging the gap between IT and OT. Purpose-built CPS security tools can extend existing IT solutions across OT systems, improving risk management and fostering greater visibility without disrupting daily operations.

3. Expand Security Governance from IT to OT

Extending IT security governance into the OT space is vital for unifying cybersecurity protocols across the organization. This integration helps close security gaps and ensures consistent governance standards, providing a more resilient defense against cyber threats.

4. Implement Strong Encryption and Access Control Measures

To protect sensitive data, manufacturers must implement robust encryption measures and access control mechanisms. Utilizing industry-standard encryption algorithms alongside digital signatures and cryptographic hashes ensures that only authorized personnel can interact with critical systems.

5. Follow Industry Standards and Regulations

Compliance with relevant industry regulations and standards is essential for safeguarding smart factories. Adhering to these guidelines not only mitigates legal risks but also strengthens defenses against cyber threats.

6. Utilize Intrusion Detection Systems

Deploying advanced intrusion detection systems (IDS) allows companies to continuously monitor data flows and flag abnormal behavior. Leveraging artificial intelligence and machine learning can enhance threat detection capabilities, enabling real-time identification and neutralization of potential threats.

7. Train Employees and Establish a Robust Recovery Plan

Employees play a crucial role in cybersecurity. Ongoing training equips workers with the knowledge to recognize security risks and respond appropriately. Additionally, a well-developed recovery plan ensures swift restoration of operations in the event of a cyberattack, minimizing downtime and financial losses.

Real-World Use Cases in Manufacturing Cybersecurity

To illustrate effective cybersecurity strategies, let’s explore some real-world use cases across three categories: Detection, Assessment, and Monitoring.

Detection: Unilever

Unilever is implementing a long-term strategy that includes creating a comprehensive digital asset registry for each plant to identify potential vulnerabilities and strengthening digital networks within larger plant systems to contain potential attacks.

Assessment: Chevron

Chevron is focused on scaling and automating its OT cybersecurity evaluations, using advanced insights to bolster protection measures. By standardizing performance metrics and reporting, Chevron can better track improvements and measure the effectiveness of its cybersecurity programs.

Monitoring: Taro Pharmaceuticals

Taro Pharmaceuticals has deployed a dedicated network monitoring solution designed to enhance the security of connected OT environments. This approach provides full network visibility, helping to reduce operational disruptions while boosting overall network security.

Conclusion

As the manufacturing industry accelerates its digital transformation, the necessity for robust cybersecurity measures becomes increasingly clear. While each organization may face unique challenges, the core principles of cybersecurity remain universal: achieving full visibility, integrating seamless IT-OT solutions, and ensuring compliance with industry regulations.

What sets resilient manufacturing units apart is their ability to partner with cybersecurity service providers that understand the intricacies of smart manufacturing environments. By collaborating with specialized teams, organizations can enhance their threat detection and response capabilities, building an infrastructure that minimizes the risk of operational downtime.

In a world where cyber threats are ever-evolving, proactive measures and strategic partnerships are essential for safeguarding the future of manufacturing.

FAQs

Q. How is cybersecurity used in manufacturing?
A. Cybersecurity in manufacturing protects industrial control systems, operational technology, and information technology environments from cyber threats. It involves implementing security protocols to safeguard interconnected networks, IoT devices, and production systems from risks like malware, ransomware, and unauthorized access.

Q. What is the role of cybersecurity in the manufacturing industry?
A. The role of cybersecurity in advanced manufacturing is to safeguard the integrity, confidentiality, and availability of production systems and sensitive data, ensuring protection against cyberattacks that could lead to financial losses or production downtimes.

Q. What is the future of cybersecurity in the manufacturing industry?
A. The future of cybersecurity in manufacturing is moving towards increased automation and AI-driven solutions, with a focus on real-time threat detection and enhanced data security through technologies like blockchain and advanced encryption.

Q. What are the benefits of cybersecurity in manufacturing?
A. Cybersecurity in manufacturing protects critical infrastructure, minimizes downtime, safeguards intellectual property, and ensures compliance with industry regulations, leading to improved operational efficiency and long-term business continuity.

Q. What are some top cybersecurity trends in manufacturing?
A. Top trends include the increased use of AI for real-time threat detection, the adoption of zero-trust architecture, and the integration of blockchain for secure data sharing across supply chains, alongside a greater emphasis on securing IoT and IIoT devices.

Author: Sudeep Srivastava
Co-Founder and Director