Digital technologies today have a significant impact on how factories work, which is changing the way things are made. As part of Industry 4.0, intelligent machines, connected sensors, real-time analytics, and cloud-integrated control environments are taking the place of or adding to old manufacturing systems. The Industrial Internet of Things (IIoT) and Operational Technology (OT) systems are the two main technologies that are driving this industrial revolution. These new technologies have made things a lot more automated, productive, and efficient. However, they have also made it easier for cyber threats to get in. Keeping IIoT and OT systems safe from cyber attacks is no longer just a technical need in today’s connected world. It is a matter of protecting critical infrastructure, keeping businesses running, and protecting people’s lives.

Industry 4.0’s demands for enhanced cybersecurity and IT infrastructure. This blog explains what cybersecurity looks like in the manufacturing sector. We will discuss the Industrial Internet of Things (IIoT), Operational Technology (OT) systems and best practices.

Why Hackers Are Targeting The Manufacturing Sector

Cybercriminals are especially interested in manufacturing because of its old infrastructure, complicated operations, and the high cost of downtime. Many factories still use machines and control systems that are decades old and weren’t made with security in mind. These systems often run on outdated operating systems, use proprietary protocols that aren’t encrypted, and have default passwords that aren’t changed very frequently.

Production environments are known to have very tight schedules and don’t have much time to waste. This often means that security updates and essential software patches are not installed on time or at all, making them vulnerable to attacks that are well known. Cybercriminals are very aware of this and often use ransomware and targeted malware to break into systems and demand payment to get things back to normal. Companies might pay ransoms because they need to get things going again quickly and don’t have the money to do so. This makes it more likely that such attacks will occur frequently in the future.

Know Your IIoT and OT: The Key to Smart Manufacturing

The industrial Internet of Things (IoT) is a network of smart devices that are built into factories. These tools gather, send, and analyse information to make things run more smoothly. These devices have cameras that can learn from their surroundings, temperature sensors, vibration monitors, and energy meters. They make predictive maintenance easier, help manufacturers use their resources better, and give them a level of insight into their production environments that they have never had before.

Operational Technology, on the other hand, is the hardware and control systems that run factory machines. Programmable Logic Controllers (PLCs), Human Machine Interfaces (HMIs), Distributed Control Systems (DCS), and Supervisory Control and Data Acquisition (SCADA) systems are all examples of these. OT systems are different from regular IT systems that deal with data and business operations because they work directly with the real world. They can, for instance, turn valves, run conveyor belts, control motors, and change heat and pressure. Because of this physical connection, any problems with Operational Technology systems can cause real damage, halt production, harm the environment, and put workers’ safety at risk.

Top Cybersecurity Threats for Manufacturing Companies

There are many threats in manufacturing, and they are constantly changing. Ransomware attacks are getting worse and worse. In some cases, they have stopped whole production lines for days or weeks at a time. Another worry that is growing is supply chain attacks, in which hackers target third-party vendors or software providers to add bad code to firmware updates or device drivers that people trust. Insider threats remain a significant problem, even if they aren’t planned. This is because employees often have access to sensitive systems and may not know how to keep their computers safe. Hackers can also exploit zero-day vulnerabilities, which are flaws in industrial software or hardware that remain unpatched until a fix is released. This makes it hard for even well-protected facilities to stay completely safe.

The IT-OT Convergence and New Threats

The merging of IT and OT networks is also a big problem. Business apps and control systems are becoming increasingly interconnected in many modern factories. This makes it easier to manage things and share data from one place, but it also makes it easier for hackers to get from less critical systems like email or procurement software to high-value OT environments. There are no suitable network segmentation and monitoring tools specifically designed for industrial settings, which exacerbates this problem. Things are even less safe now that remote access solutions have become more popular due to the COVID-19 pandemic and its aftermath. Many places now allow people to control and monitor machines remotely. They do this with open VPNs, insecure APIs, or poorly set up Remote Desktop Protocols (RDP). This gives hackers a way to get into important operations.

Building A Proactive Defence: Trust, Visibility, And Dividing Things Up

To protect against cyber risks, security needs to go beyond standard IT defences. It needs to cover everything and be proactive. The first thing you need to do is be able to see all the devices, protocols, and ways of communicating in the manufacturing site. Many companies are still unaware of the number of IIoT and OT devices on their networks or the software versions they are using. If you can’t keep track of your assets and inventory in real time, there will always be blind spots. The next most important step after gaining visibility is to divide the network into manageable parts. To keep your IT (business) and OT (production) networks separate, you need to use firewalls, secure gateways, and set up virtual LANs correctly. In OT networks, essential systems should be even more separated so that they can’t move sideways if there is a breach.

Using a Zero Trust architecture is another important part of the foundation. This means that no one or thing is automatically trusted, regardless of its location, whether inside or outside the network. You need to check all access requests against the user’s identity, the device’s integrity, the time and place of the request, and the user’s identity. In manufacturing, this means that engineers and remote technicians must use multi-factor authentication, access control policies must be rigorous, and sessions must always be monitored for any unusual activity. Antivirus software and standard intrusion detection systems don’t always work in OT environments because they need low latency and communication in real time. Businesses should spend money on cybersecurity tools that are made specifically for industrial systems and protocols. These tools can identify odd command sequences, firmware changes that shouldn’t occur, or unusual timing patterns that suggest someone is attempting malicious activity.

Setting High Standards: Using the Best Practices from Around the World

Leveraging Established Cybersecurity Frameworks

Manufacturers need to make sure that their cybersecurity practices follow well-known standards and frameworks. For example, the IEC 62443 standards for OT security architecture, the NIST SP 800-82 guidelines for industrial control systems, and the MITRE ATT&CK for ICS framework, which lists known attacker behaviours. These frameworks help you figure out risks, put protections in place, and see how well they work over time in a structured way.

Better Patch Management and Remote Access Management

Patch management is always a problem in OT because it’s not always easy to take systems offline. Virtual patching can help in these situations. It stops known exploits at the network level with security gateways or intrusion prevention systems. You should use jump servers, session recording, and credentials that only work for a short time to keep remote access safe. There shouldn’t be any default passwords, and encrypted communication protocols should be used whenever possible to stop data leaks and command interception.

Specialised Incident Response for Industrial Control Systems

It’s also very important to make a plan for how to respond to incidents that is specific to OT. A breach in OT could hurt people or damage things, but this doesn’t happen with IT systems. So, response plans should include ways to keep things separate, backup settings for important machines, and clear roles for cross-functional teams that include both cybersecurity experts and plant engineers. Teams can prepare for real-life situations and speed up recovery times by conducting tabletop exercises and drills regularly.

Enlisting AI and threat intelligence to keep the businesses safe

Lastly, threat intelligence feeds and artificial intelligence are essential for modern industrial security. AI-driven analytics can analyse a lot of sensor data and identify small changes from standard patterns that could indicate a breach or an insider threat. Global threat intelligence can help manufacturers keep up with new vulnerabilities, attack methods, and signs of compromise that are important to their industry and technologies.

Conclusion: Smart Industry Begins with Safety

In the end, it’s crucial but also very hard to keep Industrial IoT and Operational Technology systems safe in manufacturing. The stakes are high: workers’ safety is at risk, sales are lost, production stops, and the country’s infrastructure is threatened. Cybersecurity must keep pace with the manufacturing industry’s increasing intelligence and connectivity. We know for sure that an attack will happen; the only thing we don’t know is when. Companies that act now to improve their defences, promote teamwork between IT and OT teams, and use a proactive, layered security model will have the best chance of doing well in this new industrial age. Do you need assistance in enhancing the security of your manufacturing business? Contact GoAllSecure at +91 85 2723 7851 or +44 20 3287 4253 to learn more about our manufacturing cybersecurity services.