Securing the Manufacturing Plants of the Future

The advent of Industry 4.0, which has seen the convergence of Information Technology (IT) and Operational Technology (OT) and an increasing use of AI and Internet of Things (IoT) devices, is revolutionizing the manufacturing industry. 

Among many other benefits, our clients are realizing new efficiency through automation and data-driven decisions. Predictive maintenance of equipment reduces downtime and increases savings. The potential benefits are almost endless.

While these new technologies and alignment are great for the industry, they have introduced new vulnerabilities or have uncovered historically existing vulnerabilities in manufacturing environments. For example, the OT systems, which control physical processes and devices, were not originally designed with cybersecurity in mind. In many cases, much of the equipment in question is running on operating systems that are no longer supported and may have been end-of-life for a very long time. Older equipment also often lacks the latest security features and updates, making it more vulnerable to cyber threats.

As these systems become more interconnected with IT networks, they also become more exposed to cyber threats. And more IoT devices and new AI solutions mean more potential points of vulnerability. All these technologies need to be secured to prevent unauthorized access and protect sensitive data.

It may not be possible to replace all aging equipment with modernized IT systems. In some situations, cloud-based systems, which often come with improved security features, may provide an alternative to investing in new hardware. 

Effective plant security requires collaboration 

Another real challenge facing manufacturers when it comes to cybersecurity is the burden of responsibility. With many of our clients, we continue to see gaps between OT and IT. These two groups have fundamentally different functions within the business, with one responsible for designing, architecting, implementing and operating technology and the other responsible for producing the goods that the business takes to market. 

It is critical for these two groups to work together as they leverage information technology capabilities in an industrial environment. 

Ultimately, the best solution is to develop, maintain and execute a strategic plan that includes identifying and securing current operations, the devices connected to their network, network communications and who has access to these assets, as well as addressing the right ways to deal with aging infrastructure and incorporate new technologies and processes to support AI initiatives.  

Fostering ongoing collaboration between IT and OT teams is a critical first step. 

IT teams need to understand the operations of manufacturing floors and the processes required for business success. Similarly, the operations and plant leaders should focus on cybersecurity at every step of their operations.

Building a robust security strategy

Developing and maintaining a comprehensive cybersecurity strategy is iterative and ongoing. At a very high level, these are the major steps necessary for a robust security strategy. Many of these should be revisited and revised as the organization grows and the threat landscape changes.

1. Assess current security posture: Understand the current state of your organization's security. This includes identifying existing security measures, understanding your organization's risk tolerance, and evaluating the effectiveness of current security controls.
2. Identify key assets and data: Determine your organization's most critical assets and data that need protection. These could include customer data, intellectual property or business-critical applications.
3. Conduct a risk assessment: Identify potential threats and vulnerabilities that could impact your key assets and data. This should include both internal and external threats.
4. Develop security goals and objectives: Based on your risk assessment, develop clear goals and objectives for your security strategy. This should align with the overall business goals and objectives.
5. Create a security policy: Develop a comprehensive security policy that outlines the standards, guidelines and procedures to protect your organization's assets. This policy should be communicated across the organization.
6. Plan for incident response and recovery: Prepare for potential security incidents by developing an incident response plan. This should include steps for identifying, responding to and recovering from security incidents.
7. Implement security controls: Based on your security policy, implement the necessary security controls to protect your organization's assets. This could include technical controls like firewalls and encryption, as well as administrative controls like user training and access controls.
8. Monitor and review: Regularly monitor the effectiveness of your security strategy and make necessary adjustments. This could involve regular audits, penetration testing and employee training.

Stay rigorous

Building a robust security strategy is not a one-time effort. It requires continuous evaluation and adaptation to the new hardware and software capabilities and evolving threat landscapes. It's also important to regularly update policies that govern the use of technology within the organization.

CISOs and security teams must be given the authority to implement strategies and policies. They must also work closely with their operations partners to ensure security is integrated into their workflows and processes. This requires strong collaboration and knowledge-sharing across the organization.