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As factories embrace automation and connectivity, they’re becoming prime targets for cyber attacks.
Walk into any modern factory today and you’ll see automation at work – robotic arms assembling components, IoT sensors monitoring precision processes, and AI systems predicting maintenance before breakdowns occur.
But beneath this sleek machinery lies a growing vulnerability: every connected device, PLC, and production line endpoint represents a potential entry point for attackers.
Manufacturing is in the midst of a digital renaissance. Industry 4.0 promises efficiency, flexibility, and data-driven decision making, but it also merges operational technology (OT) and information technology (IT) in ways that blur old boundaries. For chief information security officers (CISOs), that convergence brings a new kind of complexity – protecting an environment where uptime is sacred and downtime can mean millions in lost revenue.
Cyber criminals have noticed. Manufacturing is now one of the most targeted industries for ransomware, intellectual property theft, and supply chain attacks. Adversaries understand that a halted production line is powerful leverage, and that manufacturers are often under pressure to resume operations at any cost. The stakes aren’t just financial; they reach into national supply chains and global trade.
Unlike traditional IT networks, factory systems were never designed with cyber security in mind. Programmable logic controllers (PLCs), industrial sensors, and SCADA systems often run legacy software that can’t easily be patched or updated. That leaves security teams struggling to protect fragile, business-critical environments without disrupting operations.
For CISOs, visibility is the first battle. A complete, real-time inventory of connected assets – including machines, controllers, and IoT endpoints – is fundamental. You can’t defend what you don’t know exists. Network segmentation can help isolate production systems from corporate networks, reducing the blast radius of a potential breach.
Another key challenge is managing legacy systems that weren’t built for modern threats. Rather than replacing expensive machinery outright, many CISOs are adopting a “secure wrapper” approach: adding gateways, access controls, and monitoring tools that bring old hardware under new protection layers. Continuous anomaly detection can also spot intrusions early without interfering with production.
Human factors remain critical, however. In manufacturing environments, operators and maintenance staff may not think of themselves as part of the cyber security team, yet their daily actions – plugging in a USB stick, ignoring an alert, or using default credentials – can open doors to attackers. Building awareness and training tailored to the plant floor is essential. Security can’t live in the server room; it has to be part of the production culture.
Supply chain integrity is another front line. Attackers increasingly infiltrate manufacturers through compromised components, software updates, or third-party suppliers. CISOs should treat vendor risk as part of operational risk, enforcing strict security requirements and conducting audits across the chain.
Resilience planning is just as vital. If an attack does occur, how quickly can the plant recover? Incident response playbooks should include procedures for isolating production systems, restoring critical configurations, and communicating with partners and regulators. Regular exercises – not just tabletops – help ensure everyone knows their role when the alarm sounds.
Cloud and AI adoption add new opportunities and new risks. Predictive maintenance platforms and digital twins rely on massive data flows between factories and the cloud. Encryption, access management, and data residency controls must evolve alongside innovation. CISOs who embed security into the design of these systems can accelerate transformation rather than slow it down.
At the end of the day, cyber security in manufacturing isn’t about compliance checklists – it’s about operational continuity and competitive advantage. The manufacturers who can operate securely, recover quickly, and protect their intellectual property will outlast those who can’t.
David Hollingworth has been writing about technology for over 20 years, and has worked for a range of print and online titles in his career. He is enjoying getting to grips with cyber security, especially when it lets him talk about Lego.
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