Turning vulnerability to cyber threats into industrial grade resiliency

Manufacturing has been the most cyberattacked industry for three consecutive years. The interconnectedness of operational technology (OT) and informational technology (IT) networks, brought on by the rise of IoT, cloud computing, and automation expose industrial systems to a range of cyber threats. Extensive financial losses and reputational damage face manufacturers unable to prevent bad actors from infiltrating their systems – but more can be done to reinforce defences according to Reidar Boldevin, Consulting Manager – Security at Columbus. Cybersecurity measures, such as network segmentation, access controls, and continuous monitoring are now imperative to protect interconnected OT and IT environments and turn the tide on malicious cyber activity in the manufacturing industry. Hacking attacks occur every 39 seconds and the manufacturing industry sees its fair share of high-profile cybersecurity incidents. Car manufacturer Toyota made headlines back in 2022 and 2023 for multiple cyberattacks, one of which involved the manufacturer having to shut down 14 factories for over 24 hours after a virus infected a file server. The lost output equalled about 13,000 vehicles – but similar losses can happen to companies of all sizes.

Cybersecurity is a company-wide effort

A common misconception among many organisations is that security is solely an IT problem, but it impacts customers and employees in plants around the world. Make UK research found that production stoppages were the most common result of a cyberattack (65%), with reputational damage ranking second (43%). What’s more, new customers now want reassurance on details of the cybersecurity in place before signing contracts. So how can manufacturers become more cyber resilient?

Manufacturing businesses can no longer delegate cybersecurity solely to their Security Operations Centre (SOC) teams. Rather, accountability for security should rest with top management across the organisation with measures being introduced at every operational level.

1. Identify cyber weak spots with a digital awareness check

The first step to improve cybersecurity measures begins with an assessment of the current level of digital readiness and an identification of areas for improvement. But knowing how to spread cybersecurity investment can be a challenge. As a top priority, manufacturers need to secure the boundary between IT and OT, and this involves safeguarding critical assets and preventing unauthorised access between systems.

Manufacturers can prioritise cybersecurity efforts by quantifying risks and assessing the impact on operations in case of outages. Without this step, manufacturing companies will accumulate several security systems that don’t meet their needs and can lead to inefficiencies and potential security risks.

Plan ahead to improve recovery times

Next up is the crucial planning stages. It’s important to have a business continuity plan to ensure continuity during critical IT incidences. This will enable essential functions to continue for a limited time and help manufacturers manage supply chain disruption more effectively. A structured disaster recovery plan, understood by every employee, should follow to establish plans for swift responses to cybersecurity incidents and disruptive events, minimising operational downtime.

Once manufacturers understand where the cyber weaknesses are, it’s time to put the defences into action.

2. Keep valuable data in safe hands with effective data governance

Manufacturing companies possess invaluable data that optimises operations and drives innovation but without proper management and security, this data poses a significant security risk. In 2023, the global average cost of a data breach totalled USD 4.45 million, a 15% increase over 3 years.

Each piece of information, whether about vendors, partners, material quality, stakeholders, or finances can paint a comprehensive picture of a company's operations, strategies, and vulnerabilities. Financial data coupled up with stakeholder information for instance, could expose vulnerabilities in financial systems or potential points of leverage for competitors. This is where effective data governance policies and procedures such as clear guidelines on data sharing and access, along with strong encryption, can prevent data from falling into the wrong hands.

Data audits can assess the sensitivity and criticality of each dataset, and evaluate existing security measures and controls. Machine learning and AI technologies can help here by identifying pattern anomalies and potential data threats, enabling proactive risk management and threat detection.

3. Get ahead on compliance and avoid the hefty fine

Cybersecurity is not only a way to protect manufacturing operations as it safeguards a company’s brand perception. Manufacturers can reinforce customer trust by staying up-to-date on the latest cybersecurity certifications and regulations as it signals to the market that the company prioritises security. The Network and Information Security Directive (NIS2) is the next legislation set to impact manufacturing organisations that operate in the EU. The Directive aims to build on previous regulations by implementing more robust cybersecurity and resilience standards, as well as more stringent reporting measures in the event of a security incident – but are manufacturers ready to comply?

The numbers don’t lie – under preparedness will weaken the supply chain Shockingly, only three-quarters of organisations across the UK, France, and Germany have yet to complete preparations ahead of the NIS2 implementation date in October 2024. When failure to comply with NIS2 can lead to fines of up to €10m ($10.5m), or 2% of an organisation’s global annual revenue, it’s important that manufacturers assess how well existing cyber measures will comply with the upcoming legislation.

As NIS2 aims to address the security of supply chains, companies will need to manage the cybersecurity risks associated with suppliers and ensure that appropriate security measures

are in place throughout the supply chain. This presents an opportunity for companies to strengthen supply chains and build resilient relationships with trusted suppliers.

4. Control access to lock down any weak links

The connectivity between OT and IT environments allows employees to work across interfaces but it also creates new risks for workstations. An infected work terminal can become a stepping stone to the production environment through lateral movement. This is why manufacturers need to control access to operational technology and monitor network interfaces.

Access management can help manufacturers introduce new authorisation measures, such as multi-factor authentication, that ensure employees only access what they need, when they need it, and from approved locations.

Don't forget about home office security

With more people working remotely and on their personal devices, it’s also important to consider the security implications of non-compliant devices. This is where stronger access controls and authentication methods can keep sensitive data and systems safe from potential threats.

5. Strengthen the frontline to create a security-first culture According to IBM’s X-Force Threat Intelligence Index report, embedded scripts in OneNote files, malicious links in PDFs, and executables disguised as document files are the most popular methods used by threat actors. All signs indicate that cyber threats are more likely to come through a company’s first line of defence – their employees. So how can manufacturers create a human firewall?

Cybersecurity measures are only effective if employees understand best practices. This is where comprehensive training programmes can help prepare employees with the knowledge and skills to adapt and excel with more secure workflows.

Don’t compromise employee usability

As with training programmes, employees will only carry out proper cybersecurity practices if they are able to do so with ease. Robust access management processes supported by efficient tools can reduce delays and frustration for employees while helping manufacturers maintain security standards. Single sign-on for instance, which consolidates access to various systems under one account, improves security and adheres to zero-trust practices without sacrificing user convenience.

Cybersecurity is firmly on the manufacturing agenda

As the manufacturing industry embarks on a new era of connectivity, the level of cyber vulnerability is only set to increase further. Manufacturers are under pressure to meet new production targets and investment in cybersecurity is seeing a de-prioritisation.

Yet it takes just one weak link for a cyber threat to bypass the doors of plants and factories and infect connected devices with disastrous results. This is why manufacturers need to pre-empt the next cyberattack with effective cybersecurity measures.