Resilience in Production: 5 Key Cybersecurity Challenges for Manufacturers

Cody Jaster

Until recent decades, operational technology (OT) – a principal element in manufacturing – remained segmented from information technology (IT). OT systems, responsible for monitoring and controlling physical machinery and equipment, were manually managed by skilled workers, operated in isolation, and secure in their simplicity.  

Fast forward to today – modern manufacturing systems are almost unrecognizable. Advanced technologies like the Industrial Internet of Things (IIoT) merge with Industrial Control Systems (ICS), making the distinction between IT security and OT infrastructure difficult. This integration promotes operational efficiency and informed decision-making, but it also exposes vulnerable systems and expands critical infrastructure attack surface. 

Over the past three years, the industrial sector has been the prime target for cyberattacks, accounting for 25.7% of all incidents. 71% of these attacks involve ransomware, threatening not just data, but also the safety and resiliency in manufacturing.

For security leaders in manufacturing, the accelerating convergence of IT and OT presents a complex set of challenges.

1. Protecting Legacy Manufacturing Control Systems

Picture your factory floor, humming with activity. At the center? Control systems, likely designed years (and in some cases, decades) ago. Long before today’s cyber threats were even imagined. It’s a common scene in manufacturing, and unfortunately, it makes for an easy target.  

These legacy systems weren’t built with cybersecurity in mind. They rarely offer the luxury of being patched or updated, leaving them open to modern attacks. The equivalent of trying to defend a medieval castle against drone warfare. 

A 2023 Microsoft report revealed 78% of industrial customers have known vulnerabilities within their networks. Nearly half of all customers are running on deprecated firmware. 

Is your organization’s risk tolerance flexible enough to gamble with those odds? Probably not. 

Here’s where security-savvy manufacturing leaders are focusing their efforts: 

  1. Attack Surface Reduction: Decreasing or eliminating insecure endpoint connections, thereby minimizing attack surface. Every open port is a potential entry point for attackers. 
  2. Access Control Improvements: Implementing robust identity and access management without adding complexity to operational network configurations or architecture. 
  3. Resilience and Business Continuity: Building systems that can quickly recover from an attack or malfunction, ensuring minimal downtime and disruption to operations. 

Use these areas of focus as foundational to improve security and reduce complexity, without sacrificing user experience.

2. Securing Critical Infrastructure from Expanding Supply Chains

Supply chains are becoming more complex and interconnected, presenting new opportunities for cyberattacks. Every new vendor, every additional user interaction, exponentially expands potential attack surface.  

 According to a Ponemon Institute report, a startling 59% of organizations have fallen victim to a software supply chain attack in recent years. 

Now, the (literal) million-dollar question: If a supply chain incident occurred today, would your security policies and practices withstand the attack? 

The answer lies in a change in thinking. Manufacturers need to embrace a zero-trust approach. This means: 

  1. Trust no one: Limit access rigorously, even for seemingly “safe” connections.
  2. Segment and conquer: Keep IT and OT networks separate. A breach in one should not compromise the other.
  3. Constant verification: Every access attempt, every data transfer, should be scrutinized. 

Adopting this zero-trust approach protects critical assets while also fortifying each link in the supply chain.

3. Managing Third-Party Risks in OT Remote Access

Remote access is often necessary for third-party vendors or engineers to keep operations running smoothly. But it comes with considerable risk. 

An innocuous remote connection could turn into a nightmare if malicious actors hijack the connection. Once they have access, they can easily gain control of OT environments, with a potential for widespread damage. 

How closely are you monitoring these remote connections? To minimize risks, it’s crucial to control access and track the activity of third-party users, ensuring only authorized personnel have entry to critical systems. 

Remember, in OT security, trust is a vulnerability. Verify everything, always.

4. Ensuring Compliance with Industry Regulations

As manufacturing processes evolve, so do the regulations governing them. Keeping up with regulatory requirements becomes a challenge. But these regulatory bodies serve a purpose. And it isn’t ticking boxes and checkbox compliance.  

Frameworks such as NIS 2 and IEC 62443 are based on practical safety and security best-practices across their specific verticals. They exist to protect consumers and businesses alike. Ensuring utilities remain uninterrupted, automated factories maintenance schedules are adhered to, and workers remain safe. 

Some frameworks have potential fines for organizational non-compliance. Others suggest individual responsibilities and liabilities, as well. But non-compliance shouldn’t be minimized to fines – legal issues and loss of trust are common byproducts. And one many companies would do well to avoid at all costs. 

An ICS security vendor should help organizations become (and remain) compliant, delivering the means to prove it, like monitoring and audit logs.  

Is your organization prepared for the cybersecurity regulations that govern your industry?

5. Integrating IT and OT Systems Without Compromising Security

The convergence of IT and OT is no longer the future – it’s happening now. And it has been for some time. It offers manufacturers unprecedented efficiency and decision-making capabilities. But this integration also presents new security risks, especially when traditional IT solutions aren’t adaptable for legacy OT systems. 

Here’s how to ensure secure communication between IT and OT without creating new vulnerabilities:  

Successful IT / OT integration isn’t simply about connecting systems – it’s focused on creating a unified, secure ecosystem where efficiency and protection go hand in hand.

How Xona Addresses These Challenges 

At Xona, we understand the unique challenges manufacturers face. Our solution segments your environment into trusted and untrusted networks, creating a secure gateway between IT and OT systems. 

Here is how we do it: 

Our technology enables secure IT-OT integration without exposing critical infrastructure to unnecessary risks. Even legacy systems with limited patching capabilities can benefit from enhanced security, ensuring your operations remain protected. 

 Xona also offers robust logging and auditing features, making it easier for manufacturers to comply with industry regulations. With our platform, you can track and document security measures, giving you peace of mind that you’re prepared for regulatory scrutiny.

Ready to Secure Your Operations?

Xona’s solution is designed to protect manufacturing environments from today’s evolving cyber threats. Interested in learning more? Schedule a 30-minute demo today, and we’ll show you how we can help secure your unique operational landscape.