Factories that have been automated for decades are now connected to the internet and various networks. Thanks to the Internet of Things (IoT), manufacturers can remotely monitor and control operations through cloud computing and artificial intelligence (AI).
While these cutting-edge technologies increase facility productivity and efficiency, the integration of IoT, robotics, and big data analytics also exposes your operations to security risks. To effectively protect your systems, it’s essential to fully understand the threats, risks, and vulnerabilities your operations face.
According to the World Economic Forum’s Global Risk Report 2023 , attacks on critical technology resources and services, such as financial systems, public safety, transportation, energy, agriculture, water, and national communications, space, and underwater infrastructure, are expected to increase in frequency alongside the rise of cybercrime.
Digitalization in the manufacturing industry
The digitalization of the manufacturing industry is truly transformative, replacing traditional production methods with advanced digital technologies to increase efficiency, flexibility, and innovation. IoT, cloud computing, and AI enable manufacturers to connect machines, streamline operations, and make real-time decisions based on data analysis.
“By 2023, nearly a quarter of global cyberattacks will target manufacturing companies . Ransomware, among the most common cyberattacks in this sector, has affected almost all subsectors , with a particularly high frequency in the production of metal products and automobiles.”
With smart operations, manufacturers can now seamlessly connect production lines, supply networks, and even consumer returns, creating fully integrated ecosystems that go far beyond automation. This allows them to reduce waste , improve product quality, and respond faster to market demands. However, this digital transformation also brings new challenges, particularly in terms of worker adaptation and industrial safety .
Industry 4.0 and cybersecurity
Industry 4.0 relies on smart, automated, and connected factories , made possible by the integration of advanced technologies such as cloud computing, big data, IoT, and artificial intelligence.
This digital revolution is improving industrial operations more than ever in terms of innovation, flexibility, and efficiency. However, as systems, devices, and networks become more interconnected, the attack surface for cyber threats expands. These systems are increasingly vulnerable to hacks, which could disrupt production, compromise sensitive data, or damage critical infrastructure, making cybersecurity a top priority in this context.
Bridging the security gap between operational technology (OT) systems—which manage physical machines but are often less secure—and information technology (IT) systems, which have historically focused on data protection, presents a major challenge.
Strict access control, network segmentation, and real-time monitoring are essential components of an integrated solution for OT systems, which are becoming increasingly vulnerable to ransomware attacks as they connect to IT networks.
Organizations must strengthen their security protocols to mitigate these risks, ensuring that devices such as industrial robotic arms and HMIs (human-machine interfaces) are properly protected and authenticated. In the hybrid digital and physical environment of Industry 4.0, IT and OT security are now equally crucial.
Cybersecurity risks in smart manufacturing
Before exploring solutions and strategies to protect smart factories from cyber threats, it is essential to understand the different types of risks.
Here are the 10 most common cyber threats in smart manufacturing :
1. Ransomware attacks
Smart manufacturing systems are particularly vulnerable to ransomware attacks, where malicious actors take control of critical data or systems and demand payment to unlock them. This can lead to production shutdowns, resulting in significant financial losses and a significant decrease in productivity.
2. Industrial espionage
One of the major risks associated with smart factories is the theft of trade secrets, intellectual property, and sensitive data. Cybercriminals can infiltrate networks to steal confidential designs, production techniques, or customer information, which can damage a company’s reputation and compromise its ability to remain competitive.
3. Malware and viruses
In smart factories, malware infections can spread rapidly across interconnected devices and systems, disrupting workflows, damaging hardware, and compromising data integrity. Legacy OT systems, often neglected and rarely updated, are particularly vulnerable to these threats.
4. Supply chain vulnerabilities
Complex, digitally connected supply networks are often at the heart of smart manufacturing. Hackers exploit the supply chain as an entry point to take over vital systems. For example, a cyberattack targeting a single partner or supplier can compromise the entire manufacturing process.
5. Unauthorized Access
Systems used in the manufacturing industry can be vulnerable to intrusion by unauthorized users due to insufficient access control and authentication procedures. Unsecured remote access points, outdated software, and weak passwords can allow hackers to access critical computers and operations.
6. Internal threats
Whether intentionally or accidentally, workers or contractors with access to private systems can jeopardize security. Negligence, malice, or simple human error can compromise data, disrupt operations, or leave systems vulnerable to cyberattacks.
7. Disaster Denial of Service (DDoS) Attack
Distributed Denial of Service (DDoS) attacks can overload a factory’s network infrastructure, leading to partial or complete shutdowns. With communication between machines and systems disrupted, production operations are severely hampered.
8. Vulnerabilities of IoT devices
Internet of Things (IoT) devices, such as sensors and connected machines, are essential components of smart factories. However, many IoT devices have lax security measures, making them easy for hackers to exploit. This opens new avenues of entry for more serious attacks on the factory network.
9. Phishing and social engineering
Social engineering and phishing attempts can trick employees into disclosing sensitive information or clicking on suspicious links, compromising their login credentials or allowing malware to infiltrate the corporate network.
10. Insecurity of existing systems
Many industrial sites continue to use outdated OT systems that are not designed to integrate with modern IT networks. These systems represent a weak point in the overall security infrastructure, as they often lack the necessary security measures to counter modern cyberattacks.
5 Ways to Secure Your Industrial Cybersecurity
A wide range of tips and techniques can be implemented to strengthen the security of a manufacturing network.
1. Leverage artificial intelligence for threat detection
Artificial intelligence is growing rapidly across many industries, improving both manufacturing and predictive maintenance through advanced data analytics and machine learning capabilities. In the manufacturing industry, it can also be used to identify and manage threats.
As a powerful cybersecurity tool , AI can quickly detect and remediate potential risks. It continuously monitors industrial control systems (ICS) and network traffic for irregularities that could indicate a cyberattack. Additionally, AI has the ability to automatically respond to attacks by restricting access to compromised devices or neutralizing malicious activity before it spreads, protecting industrial environments while minimizing downtime.
2. Adopt a zero trust architecture
Zero trust architecture is based on the principle that no system, device, or user—whether on or off the corporate network—should be trusted by default. This strategy mitigates the risk of unauthorized access to critical systems in industrial environments by thoroughly vetting each access request before approving it.
By adopting measures such as rigorous identity verification, network segmentation, and least-privileged access, manufacturers can reduce the attack surface and strengthen the security of IT and OT systems.
Ensuring reliable and secure data transfer from OT devices to IT-based cloud services is a major challenge for system integrators in the IIoT (Industrial Internet of Things). For example, Moxa offers robust, cloud-ready IIoT gateways and long-lifecycle software, providing fast and secure IIoT solutions. Moxa strengthens OT/IT security in the following ways:
- Securing network infrastructure through both device-by-device and layer-by-layer protection, ensuring the security of data traffic.
- Protect critical equipment with defenses tailored to OT protocols, including packet inspection and pattern-based protection.
In compliance with the IEC-62443 standard, Moxa combines expertise in industrial networking and cybersecurity to continuously improve security, while collaborating with TXOne Networks to address IT/OT security needs. They offer centralized network management, secure edge connectivity, and protection via IPS/IDS systems. Learn more about their edge connectivity devices, which include protocol converters, serial-to-Ethernet servers , and wireless solutions such as the SDS-3008 and AWK series , all of which are IEC 62334-4-2 certified. For more information, click here .
3. Secure Cyber-Physical Systems (CPS)
Smart manufacturing relies on cyber-physical systems (CPS), which integrate digital control with physical processes. However, the increasing interconnectivity of these systems increases the likelihood of cyberattacks impacting machinery. To protect these cyber-physical systems, it is essential for manufacturers to adopt measures such as strong encryption, frequent software updates, and real-time monitoring to detect vulnerabilities and thwart attacks. Ensuring operational security and integrity also requires robust communication protocols between physical equipment and its digital counterparts.
4. Segmentation and micro-segmentation of networks
By segmenting networks into smaller, isolated areas, it’s possible to prevent a single point of failure from affecting an entire industrial system. This approach is further enhanced by micro-segmentation, which minimizes the potential impact of breaches by applying fine-grained security policies at the workload level. This is particularly important for protecting OT systems, which manage critical production processes and are often the target of intrusions when integrated into larger IT networks.
5. Regular security audits and patches
Conducting regular security audits is essential to identify and address potential vulnerabilities within industrial systems. These audits should include verifying access limits, ensuring compliance with security policies, and updating software patches. To strengthen security, it is crucial to quickly apply these patches to both IT and OT systems, especially those that are cyber-physical and vital to industrial operations. In a constantly evolving threat landscape, continuous assessment is essential to maintain a robust security posture.
Challenges of Implementing Cybersecurity in Smart Factories
Implementing cybersecurity in smart factories poses several challenges. The attack surface increases significantly when IT and operating systems are integrated, making securing physical equipment and digital networks more complex.
Legacy operational technology (OT) systems, when connected to contemporary IT networks, become particularly vulnerable, as they often lack adequate security measures. This poses a major challenge for manufacturers, who must navigate the balance between maintaining operational efficiency and ensuring robust security.
Ensuring secure data transfer, implementing effective network segmentation, and maintaining real-time monitoring are critical priorities, but difficult to achieve in a constantly changing environment.
Cybersecurity poses a major obstacle to the adoption of smart factories, as it is essential to manage not only external threats, but also internal ones. Securing IoT devices and constantly monitoring evolving cyber threats are essential requirements. To meet these requirements, companies must make ongoing investments in security technologies and staff training.
Essential steps to ensure cybersecurity in the smart factory
To conclude what has been discussed in this article, here are some exemplary measures to take to overcome the challenges related to the implementation of cybersecurity in smart factories:
- Adopt a zero trust architecture : Implement the “never trust, always verify” philosophy by ensuring that all users and devices connected to the factory network are subject to strict access controls, continuous monitoring, and robust authentication processes.
- Segment IT and OT networks : Establish a clear separation between IT and OT systems through network segmentation to minimize the risk of lateral movement in the event of a breach. This helps reduce risk and protect critical OT systems.
- Regular security audits and risk assessments : Regular security audits are essential to identify weaknesses in OT and IT systems. Risk assessments also help verify compliance with industry standards and prioritize areas requiring improvement.
- Use AI for threat detection : Leverage AI and machine learning to automate responses to potential cyber threats, identify anomalies, and monitor networks in real time. AI can strengthen cybersecurity defenses by quickly detecting trends and potential vulnerabilities.
- Secure IoT devices : For each connected IoT device, implement strong authentication, data encryption, and frequent firmware updates to prevent unauthorized access and manipulation of factory systems.
- Educate and train employees : To ensure a better understanding of phishing, social engineering, and other cyber threats, it is essential to hold regular cybersecurity training sessions. A security-aware workforce is crucial for reducing the risk of intrusion.
- Establish incident response plans : In the event of a cyberattack, it’s crucial to clearly define responsibilities and procedures in your response plan. This helps ensure rapid containment and recovery, minimizing the impact on operations.
