The Hidden Vulnerabilities on Your Shop Floor
If you’re a manufacturer, your CNC machines, PLCs, and other shop floor systems are the beating heart of your business. These systems keep your production lines running smoothly, ensuring you meet tight deadlines and deliver on customer expectations. But here’s a shocking truth: most IT providers don’t know how to secure them.
While traditional IT providers excel at securing office systems—like email servers, desktop computers, and cloud storage—they often ignore or misunderstand the unique needs of operational technology (OT). This oversight leaves your shop floor exposed to cyber threats, operational downtime, and even compliance risks.
In this post, we’ll uncover why traditional IT providers often fail manufacturers, the hidden vulnerabilities in your shop floor systems, and the practical steps you can take to protect your operations.
The Unique Challenges of Securing Shop Floor Systems
Manufacturing environments are vastly different from office settings. Yet, many IT providers approach them as if they are the same. This leads to critical gaps in security and functionality. Here’s why:
1. IT Prioritizes Confidentiality Over Availability
Traditional IT security follows the C-I-A model: Confidentiality, Integrity, and Availability. This makes sense in an office environment, where protecting sensitive data—like emails and financial information—is a top priority.
But in manufacturing, the priorities are different. Availability comes first. Your CNC machines, PLCs, and robotics need to operate without interruption, as even a single hour of downtime can result in thousands of dollars in losses.
Example:
One manufacturer we worked with experienced downtime after their IT provider applied a routine security patch. The patch caused compatibility issues with their CNC machines, halting production for six hours. The resulting loss in productivity and delayed deliveries cost the company over $25,000.
2. Shop Floor Systems Are Not Desktop Computers
Unlike office computers, shop floor systems often run on legacy software or proprietary operating systems. Many CNC machines and PLCs were not built with cybersecurity in mind because they were designed to last decades—not to keep up with modern-day threats.
When IT providers apply standard protocols like automatic updates, antivirus scans, or restrictive firewalls, these machines often malfunction. This can lead to system crashes, production delays, and costly repairs.
Fact:
Hackers target these vulnerabilities because shop floor systems are often the easiest entry point into a manufacturing network.
3. Network Segmentation Is Often Overlooked
One of the biggest security gaps in manufacturing is the lack of proper network segmentation. Many manufacturers have their shop floor systems connected to the same network as their office systems. This makes it easy for malware or ransomware to spread from office computers to CNC machines and other OT systems.
Without proper segmentation, a single breach can bring your entire operation to a standstill.
Why Manufacturers Are Prime Targets for Cyberattacks
Manufacturing has become one of the most targeted industries for cybercriminals. Hackers view manufacturers as high-value targets for two main reasons:
- Critical Dependence on Uptime: Manufacturers can’t afford downtime. Every hour of halted production means lost revenue, missed deadlines, and damaged customer relationships. This makes manufacturers more likely to pay ransoms to restore operations quickly.
- Undervalued Cybersecurity on the Shop Floor: While manufacturers often invest in securing office systems, shop floor systems like CNC machines and PLCs are left vulnerable. These legacy systems were never designed to defend against modern cyber threats, making them an easy entry point for attackers.
Who Are the Hackers?
- State-Endorsed Groups: Some hackers are funded or supported by nation-states (Russia, North Korea, China, & Iran) seeking to disrupt supply chains, steal intellectual property, or gain economic advantages. Manufacturing is a key target because it powers critical industries like aerospace, defense, and infrastructure.
- Financially Motivated Cybercriminals: Ransomware gangs and organized cybercriminals target manufacturers for quick payouts. These attackers lock down shop floor systems and demand hefty ransoms, knowing the urgency of restoring production will often force manufacturers to pay.
- Opportunistic Threat Actors: These are hackers exploiting basic vulnerabilities, such as open ports on CNC machines or outdated PLC firmware. While less sophisticated, their attacks can still cause severe disruptions if systems aren’t properly secured.
3 Cybersecurity Solutions to Protect Your Shop Floor
Now that we’ve outlined the problems, let’s look at the solutions. Here are three practical steps to secure your shop floor systems and protect your operations:
1. Partner with an IT Provider Who Understands Manufacturing
Not all IT providers are equipped to handle the unique challenges of shop floor security. Manufacturers need a provider who specializes in operational technology and understands the importance of uptime, safety, and compliance.
What to Look For in an IT Provider:
- Experience working with CNC machines, PLCs, and other OT systems.
- A track record of implementing secure remote access and network segmentation.
- A commitment to prioritizing availability and safety over traditional IT goals.
2. Segment Your Networks
Creating a defensible architecture by network segmentation is one of the most effective ways to prevent cyberattacks from spreading. By isolating your OT systems from your office systems, you can contain breaches and minimize their impact.
How to Implement Network Segmentation:
- Use firewalls to create separate zones for OT and IT systems.
- Limit access to each zone based on user roles and permissions.
- Regularly test your segmentation to ensure it’s working as intended.
3. Back Up Your Shop Floor Systems
Having secure backups of your CNC machine configurations, PLC programs, and other critical data is essential. These backups ensure that you can quickly restore operations in the event of a breach or system failure.
Best Practices for Backups:
- Create both on-site and off-site backups.
- Automate your backup process to ensure consistency.
- Test your backups regularly to make sure they can be restored.
Protect Your Production Line
Manufacturing environments require a different approach to cybersecurity—one that prioritizes uptime, safety, and tailored solutions for shop floor systems. Traditional IT providers often fail to meet these needs, but by partnering with the right provider and implementing best practices, you can safeguard your operations and stay ahead of cyber threats.
Take the first step today to protect your business and keep your production line running smoothly.
