With threats to the manufacturing industry growing more sophisticated and supply chains under greater pressure than ever before, a unified approach to security across both IT and OT environments is vital for detecting new threats and vulnerabilities.

The manufacturing industry faces cyber-attacks not only from financially motivated threat actors but also from nation-states, hacktivists, and competitors engaging in industrial espionage. As these attacks become more sophisticated and difficult to detect, with threat actors constantly developing new tactics, defenders are struggling to secure their systems.

Cyber-attacks that originate in the IT layer are increasingly impacting industrial systems on the factory floor, highlighting the urgent need for a unified system that protects both IT and OT environments.

Manufacturing cyber-attack example

The EKANS ransomware strain that disrupted manufacturing facilities around the world in 2020 resulted in a dramatic decline in production and incurred huge costs. This attack directly targeted ICS vulnerabilities, with the ability to attack 64 specific ICS mechanisms in its kill chain.

As the scale of attacks continues to increase, security teams are becoming more stretched, and a skills gap is developing between IT staff and OT engineers. Today’s manufacturing organizations need technology that can illuminate cyber-threats across the entire business, uplifts security teams and bridge that skills gap, providing actionable insights to help remediate the most pressing security incidents.

The Fourth Industrial Revolution, or Industry 4.0, is a transformative phase in the manufacturing industry characterized by the integration of advanced technologies like artificial intelligence (AI), the Internet of Things (IoT), and big data analytics. These innovations drive unprecedented efficiency, automation, and connectivity, fundamentally reshaping the manufacturing.

However, this also introduces significant cybersecurity challenges. Because manufacturing systems become more interconnected, they generate and store vast amounts of sensitive data across various platforms. This expansion of data points and storage locations creates new vulnerabilities that cybercriminals can exploit. Moreover, the seamless connection of new technologies to existing infrastructure can expose older systems to potential threats. Consequently, security practitioners and manufacturing facilities are faced with an expanding attack surface that require skilled personnel and intelligent solutions to bolster defenses.

Cyber threats to manufacturing infrastructure could disrupt production, compromise sensitive data, or lead to significant financial losses. By securing these systems, manufacturers can ensure the continuity of operations, maintain data integrity, and protect intellectual property.  

Wearable Sensor and Computing Devices

Wearable sensors and computing devices are revolutionizing the manufacturing industry by enhancing real-time monitoring and increasing worker safety. These devices, often integrated into clothing or equipment, collect data on environmental conditions, worker health, and equipment performance. This data enables proactive maintenance and rapid response to potential hazards, reducing downtime and preventing accidents. However, the widespread use of wearable technology also introduces new cybersecurity risks, as sensitive data can be intercepted or manipulated if not properly secured.

Artificial Intelligence/Machine Learning

Artificial Intelligence (AI) and Machine Learning (ML) are driving automation and optimization in manufacturing processes. AI systems can analyze vast amounts of data to identify patterns, predict equipment failures, and optimize production schedules, leading to significant efficiency gains. Similarly, learning models improve over time, making manufacturing processes more adaptive and resilient. However, the reliance on AI/ML systems also creates new vulnerabilities, as these systems can be targeted by cyber-attacks that corrupt data inputs or manipulate outputs, potentially causing widespread disruption.  

Industrial Internet of Things (IoT)

The Industrial Internet of Things (IoT) connects machines, sensors, and devices across manufacturing facilities, enabling seamless communication and data exchange. This connectivity allows for better monitoring, control, and automation of production processes. However, the increased connectivity also expands the attack surface, making IoT devices prime targets for cybercriminals. Ensuring the security of IoT networks is crucial to prevent unauthorized access, data breaches, and potential disruptions to manufacturing operations.

Virtual and Augmented Reality

Virtual and Augmented Reality (VR/AR) technologies are being used in manufacturing to improve design processes, training, and maintenance. VR allows for immersive simulations, enabling engineers to design and test products in a virtual environment. AR provides real-time information and guidance to workers, enhancing their ability to perform complex tasks. Despite their benefits, VR/AR systems rely heavily on network connectivity and data sharing, making them susceptible to cyber threats. Protecting these systems is essential to ensure the accuracy of data and the safety of operations.

Big Data Analytics

Big Data Analytics enables manufacturers to harness the power of data to make informed decisions. By analyzing large datasets from various sources, manufacturers can optimize processes, reduce waste, and improve product quality. However, the use of big data also raises security concerns, as the aggregation of data from multiple sources can create vulnerabilities. Securing the data at rest and in transit is vital to protect against breaches and ensure the integrity of the insights derived from analytics.

5G Cellular Networks

The advent of 5G cellular networks is set to revolutionize manufacturing by providing faster, more reliable, and low-latency connectivity. 5G enables real-time communication between devices, supports massive IoT deployments, and enhances the capabilities of AI and machine learning in manufacturing environments. However, the deployment of 5G also introduces new security challenges, as the increased connectivity and bandwidth create more entry points for cyber-attacks. Implementing robust security measures is essential to protect the manufacturing infrastructure as it becomes increasingly reliant on 5G technology.

Many manufacturing organizations still rely on decades-old bespoke OT systems that were designed without security in mind. Traditionally, decision makers in this industry have emphasized performance and physical safety over security, but as OT and IT converge, these concepts are becoming more intertwined.

In contrast to OT, Information Technology (IT) security typically prioritizes confidentiality, integrity, and availability (CIA). While both OT and IT share concerns about availability and integrity, OT security places greater emphasis on control, as any disruption could lead to physical damage, safety hazards, or significant downtime in manufacturing processes. The need to secure these physical assets against cybersecurity risks is paramount, as a breach could have catastrophic consequences for both the manufacturing sector and its broader supply chain.

The growing complexity of manufacturing systems has resulted in extremely bespoke and specialized network infrastructures, and in many cases the systems are being operated and managed by manufacturing specialists rather than the IT function. from regular PLC traffic, to distributed IIoT sensor grids.

Other challenges include the following:

Difficulty Maintaining Accurate Real-Time OT/IIoT System and Device Inventories

One of the key cybersecurity risks for the manufacturing sector is the challenge of maintaining accurate, real-time inventories of OT and Industrial Internet of Things (IIoT) systems and devices. With the proliferation of connected devices in manufacturing environments, it becomes increasingly difficult to track and monitor every asset. This lack of visibility can lead to gaps in security, where unmonitored or unknown devices become entry points for cyber threats. As the manufacturing sector continues to adopt more IIoT devices, the importance of maintaining comprehensive and up-to-date inventories grows, as does the complexity of managing these assets securely.

Insufficient Threat Intelligence on OT and IIoT Infrastructure Attacks

Another significant challenge in the manufacturing sector is the insufficient threat intelligence regarding OT and IIoT infrastructure attacks. Traditional IT systems benefit from a wealth of threat intelligence resources, but OT environments often lack similar levels of insight. This gap in threat intelligence leaves manufacturers vulnerable to emerging cybersecurity risks specifically targeting their OT and IIoT systems. Without accurate and timely information on potential threats, the manufacturing sector may struggle to defend against sophisticated attacks that could disrupt operations, compromise safety, and result in substantial financial losses. Strengthening threat intelligence capabilities tailored to OT and IIoT environments is crucial to mitigating these risks and protecting critical manufacturing infrastructure.

Increased Cybersecurity Training

Employee awareness is a critical component of cybersecurity for manufacturing. Regular and comprehensive training programs can help staff recognize potential cyber threats, such as phishing attacks, and understand the importance of following security protocols. By fostering a culture of security, manufacturers can reduce the risk of human error, which is often a key factor in cyber incidents.

Enhanced Detection and Analysis

To stay ahead of cyber threats, manufacturers should implement advanced detection and analysis tools. These tools can monitor network traffic, identify unusual activities, and provide real-time alerts, enabling a quick response to potential breaches. Enhanced detection capabilities are essential for safeguarding manufacturing infrastructure and minimizing the impact of cyber-attacks.

Update Applications Regularly

Regularly updating software and applications is crucial to address vulnerabilities that cybercriminals could exploit. Manufacturers should prioritize timely patches and upgrades to their systems, including OT and IIoT devices, to protect against known vulnerabilities. Keeping systems up to date is a fundamental practice in maintaining strong cybersecurity for manufacturing.

Conduct Risk Assessments

Conducting regular risk assessments helps manufacturers identify and address potential vulnerabilities in their systems. These assessments evaluate the likelihood and impact of various cyber threats, enabling companies to prioritize their security efforts and allocate resources effectively. Regular risk assessments are essential for maintaining a proactive approach to cybersecurity.

Implement Effective Cybersecurity Tools

Manufacturers should invest in robust cybersecurity tools designed to protect their unique operational environments. Tools such as firewalls, intrusion detection systems, and encryption technologies can help secure critical data and infrastructure. Implementing a comprehensive suite of security tools is vital to safeguarding manufacturing operations against cyber threats.

Discover more about the OT cybersecurity landscape and learn criteria for evaluating OT cybersecurity tools in the white paper "OT Security Guide: Strategies & Case Studies."

At a European medical manufacturing firm, an administrative assistant received a targeted phishing email in relation to payments with an invoice attached. Believing the attachment to be authentic, they clicked on it and unwittingly downloaded a fast-acting malware that had bypassed all other security controls.

The sophisticated malware was specifically targeting the organization’s intellectual property, which included highly confidential medical formulas. Should these assets have been compromised, the firm would have experienced significant damage to their competitiveness and reputation.

Once the malware was downloaded, the device rapidly began connecting to a rare external destination while trying to move laterally to other environments. Within two seconds, Darktrace’s AI identified the emerging threat and raised a clear alert to the security team, who were able to take the device offline before the malware could spread.

Darktrace AI protects the critical and complex cyber-physical ecosystems of hundreds of manufacturers around the globe. Protocol and technology agnostic, the AI detects in-progress attacks across the digital business, instantly alerting security teams to nascent threats.  

Darktrace passively learns what ‘normal’ looks like across connected cyber-physical devices, operational technology, users, and IT systems, and all the interactions between them. By learning ‘on the job’, Darktrace does not require additional training, added data sets, or tuning; instead, it identifies the subtle signals of emerging attack in real time – no matter how novel or sophisticated the threat

To safeguard your manufacturing company’s operations, contact Darktrace today to learn more about their cybersecurity solutions and request a demo.