Factories that have been automated for decades are now connected to the Internet and other networks. The Internet of Things (IoT) allows manufacturers to monitor and control factory operations remotely, using cloud computing and artificial intelligence (AI). Although these cutting-edge solutions enhance the production and efficiency of manufacturing facilities, the use of technologies like IoT, robotics and big data analytics also brings a security risk to your operations. To ensure the security of your systems, you need to understand the threats, risks, and vulnerabilities of your operations.
According to the Global Risk Report 2023 by Economic World Forum, attacks against critical technology-enabled resources and services, such as those targeting financial systems, public security, transportation, energy, agriculture and water, and domestic, space-based, and undersea communication infrastructure, are expected to increase in frequency along with cybercrime.
Digitalisation in Manufacturing
Digitalisation in manufacturing is transformative as it changes traditional production methods by integrating with advanced digital technologies to enhance efficiency, flexibility, and innovation. With IoT, cloud computing, and AI, manufacturers are able to connect machines, streamline operations, and make data-driven decisions in real time.
“In 2023, about a quarter of all cyberattacks worldwide involved manufacturing companies. Ransomware, one of the most common types of cyberattacks in this sector, hit almost all subsectors, targeting metal products and automotive productions more frequently.”
Statista, Cybercrime and the manufacturing industry worldwide – Statistics & Facts
Thanks to smart operations, manufacturers can now effortlessly connect production lines, supply networks, and even consumer feedback loops into completely connected ecosystems, beyond automation. Manufacturers are able to reduce waste, enhance product quality, and respond to market demands faster as a result. But there are also new difficulties brought about by this digital transition, especially with regard to worker adaptation and industrial security.
Industry 4.0 and Cybersecurity
Industry 4.0 is all about automated and networked smart factories, created through the integration of advanced technologies like cloud computing, big data, IoT, and artificial intelligence. Industrial operations are now more than ever enhanced with innovation, flexibility, and efficiency because of this digital revolution. On the other hand, as systems, devices, and networks become more connected, so does the attack surface that cyber threats can exploit. Given that these linked systems are increasingly susceptible to hacks that could impede production, jeopardise sensitive data, or destroy vital infrastructure, cybersecurity has grown in importance in this environment.
Closing the security gap between OT systems—which manage physical machinery but are frequently less secure—and IT, which has historically concentrated on data protection, is a major challenge. Strong access control, network segmentation, and real-time monitoring are essential components of an integrated solution for OT systems, as they grow more vulnerable to ransomware assaults as they are connected to IT networks. Organisations must strengthen security procedures in order to combat these risks, making sure that devices such as industrial robot arms and HMIs are adequately protected and authenticated. To protect Industry 4.0’s hybrid digital and physical environment, IT and OT security are equally important.
Cybersecurity Risks in Smart Manufacturing
Before delving into the solutions and ways of protecting smart factories against cyber threats, it’s important to understand the different types of risks.
Here are the 10 most popular cyber threats in smart manufacturing:
1. Ransomware Attacks
Smart manufacturing systems are prone to ransomware attacks, in which malicious parties take control of crucial data or systems and demand payment in order to unlock them. This may cause production to stop, resulting in large financial losses and lost productivity.
2. Industrial Espionage
One of the biggest risks in smart factories is the theft of trade secrets, intellectual property, and sensitive data. Cybercriminals may breach networks to take advantage of confidential designs, production techniques, or client information, which could harm a company’s standing and ability to compete.
3. Malware and Viruses
In smart factories, malware infections can proliferate swiftly throughout networked devices and systems, upsetting workflows, causing hardware damage, or jeopardising data integrity. Particularly vulnerable are legacy OT systems, which are typically not updated.
4. Supply Chain Vulnerabilities
Digitally connected, intricate supply networks are frequently the foundation of smart manufacturing. Because hackers utilise the supply chain as a point of entry to get vital systems, a cyberattack on a single partner or supplier has the potential to undermine the entire manufacturing process.
5. Unauthorised Access
Systems used in manufacturing can be compromised by unauthorised users due to weak access control and authentication procedures. Insecure remote access points, unpatched software, and weak passwords can provide hackers access to vital computers and operations.
6. Insider Threats
Unintentionally or purposely, workers or contractors having access to private systems may compromise security. Negligence, malicious intent, or human error can result in data compromise, disruptions to the system, or vulnerability to cyberattacks.
7. Distributed Denial of Service (DDoS) Attacks
DDoS assaults have the ability to overload the network infrastructure of a factory, resulting in partial or total shutdowns. Production activities are severely hampered as a result of the breakdown in machine and system communication.
8. IoT Device Vulnerabilities
Internet of Things (IoT) devices, such sensors and connected machinery, are critical components of smart factories. Because many IoT devices have lax security measures, hackers can easily exploit them, opening up new avenues of entry for more extensive attacks on the factory’s network.
9. Phishing and Social Engineering
Social engineering and phishing attempts have the ability to fool staff members into disclosing private information or clicking on dubious links, which can compromise login credentials or allow malware to enter the manufacturing network.
10. Legacy System Insecurity
Many industrial settings continue to use antiquated legacy OT systems that are not intended to be integrated into contemporary IT networks. These systems are a weak area in the overall security infrastructure because they frequently lack the security measures required to fight against modern cyberattacks.
5 Ways for Securing Industrial Cybersecurity
There are many tips and techniques that can be employed to improve the security of a manufacturing network.
1. Leverage AI for Threat Detection
Artificial intelligence (AI) is growing in many sectors, and it is enhancing manufacturing and predictive maintenance by providing more advanced data analysis and machine learning capabilities. It also can be used to identify and address threats in manufacturing. AI is a tremendous weapon in cybersecurity, especially when it comes to quickly recognising and addressing possible risks. AI is capable of monitoring industrial control systems (ICS) and network traffic for irregularities that could point to a cyberattack. In addition, it has the ability to automatically respond to attacks by limiting access to hacked devices or stopping malicious activity before it spreads, protecting industrial environments while minimising downtime.
2. Implement Zero Trust Architecture
The premise of zero trust architecture is that no system, device, or user—whether on or outside the company network—should be trusted by default. This strategy reduces the possibility of unwanted access to vital systems in industrial settings by vetting each access request before approving it. Manufacturers can lower the attack surface and improve the security of both IT and OT systems by implementing stringent identity verification, network segmentation, and least-privilege access.
Getting 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 instance, Moxa addresses this with robust, cloud-ready IIoT gateways and long-lifecycle software, offering quick and secure IIoT solutions. Moxa strengthens OT/IT security by:
- Securing network infrastructure with device-by-device and layer-by-layer protection, ensuring safe data traffic.
- Protecting critical assets with OT protocol-specific defenses, including packet inspection and pattern-based protection.
Following the IEC-62443 standard, Moxa unites industrial networking and cybersecurity expertise, enhances security continuously, and collaborates with TXOne Networks to meet IT/OT security needs. Their offerings include centralised network management, secure edge connectivity, and protection via IPS/IDS systems.
Moxa has edge connectivity devices, including protocol converters, serial-to-ethernet servers, and wireless solutions like the SDS-3008 and AWK-series (IEC 62334-4-2 certified). More information here.
3. Secure Cyber-Physical Systems (CPS)
Smart manufacturing relies on cyber-physical systems (CPS), which integrate digital control with physical processes. Nonetheless, the likelihood of cyberattacks impacting actual machinery rises as a result of this interconnection. Strong encryption, frequent software updates, and real-time monitoring to identify weaknesses and thwart assaults are all necessary for manufacturers to safeguard CPS. Maintaining operational safety and integrity requires strong communication protocols between physical equipment and their digital counterparts.
4. Network Segmentation and Micro-Segmentation
By dividing networks into smaller, more isolated zones, it is possible to keep an industrial system from being affected by a single damaged location. This is enhanced by micro-segmentation, which lessens the effect of possible breaches by implementing fine-grained security policies at the workload level. This is especially crucial for safeguarding OT systems, which manage vital production processes and are frequently targets of intrusions when linked to larger IT networks.
5. Regular Security Audits and Patching
Frequent security audits assist in locating and resolving possible vulnerabilities in industrial systems. This includes checking access limits, making sure security rules are followed, and keeping software patches current. Closing security holes requires prompt patching of both IT and OT systems, particularly in cyber-physical systems that are vital to industrial operations. In the quickly changing threat landscape, ongoing evaluation contributes to the maintenance of a solid security posture.
Challenges in Implementing Smart Factory Cybersecurity
There are a number of difficulties in implementing cybersecurity in smart factories. The attack surface is increased when IT and OT systems are integrated, making it more challenging to secure physical equipment as well as digital networks. When connected to contemporary IT networks, legacy OT systems are insecure because they frequently lack integrated security safeguards. It is difficult to maintain operational efficiency while guaranteeing safe data transfer, network segmentation, and real-time monitoring.
Cybersecurity is a major barrier to the adoption of smart factories since it is also necessary to manage insider threats, secure IoT devices, and stay up to date with developing cyber threats. These requirements necessitate ongoing investment in technology and training.
Steps to Take for Successful Smart Factory Cybersecurity
To conclude what has been mentioned in this paper, here are exemplary steps you can take to overcome challenges in implementing cybersecurity in smart factories:
- Adopt a Zero Trust Architecture – implement a “never trust, always verify” philosophy by making sure that all users and devices connected to the factory network have rigorous access controls, ongoing monitoring, and authentication.
- Segment IT and OT networks – separate IT and OT systems via network segmentation to lower the possibility of lateral movement in the event of a breach. By doing this, dangers are lessened and vital OT systems are safeguarded.
- Regular security audits and risk assessments – to find weaknesses in OT and IT systems, regularly conduct security audits. Risk assessments can assist in ascertaining conformity with industry standards and prioritising important areas for improvement.
- Deploy AI for threat detection – utilise AI and machine learning to automate reactions to possible cyber threats, identify anomalies, and monitor networks in real time. AI can strengthen cybersecurity defences by seeing trends and possible security holes fast.
- Secure IoT devices – for every IoT device that is connected, implement strong authentication, encryption, and frequent firmware updates to stop unwanted access and manipulation of factory systems.
- Educate and train employees – to increase staff understanding of phishing, social engineering, and other cyberthreats, conduct frequent cybersecurity training. Reducing insider risks requires a workforce that is security-conscious.
- Establish incident response plans – in the case of a cyberattack, clearly outline responsibilities and procedures in your incident response plan. This guarantees quick containment and recovery with the least amount of operational impact.
This article provides simple informative guidelines on how to protect yourself from cyber threats in manufacturing settings. However, to ensure the proper security measures are in place, it is recommended that manufacturers conduct a cybersecurity assessment to determine their specific risks and vulnerabilities.
