The integration of operational technology (OT) with information technology (IT) has revolutionized industrial automation. Manufacturing plants and industrial facilities are now more efficient than ever, thanks to connected devices, SCADA systems, and advanced automation. However, this increased interconnectivity has also introduced significant cybersecurity risks that threaten operations, safety, and financial stability.
This article explores the evolving cybersecurity challenges faced by industrial automation and highlights the steps manufacturers must take to protect their systems from modern cyber threats.
The Evolution of Industrial Cybersecurity
In the past, industrial equipment and controls operated as standalone systems, with minimal connectivity to the broader IT network. Before the rise of the Internet and interconnected operations, disrupting an industrial process required physical access. Today, with the integration of OT devices into IT networks, industrial plants have become prime targets for cyberattacks.
While this connectivity has improved efficiency, it has also opened the door to potential attacks that can:
- Disrupt process control systems.
- Impair automated assembly lines.
- Cause plant shutdowns and significant productivity losses.
- Create health and safety risks for employees.
SCADA systems, often referred to as the “brains” behind industrial operations, are particularly vulnerable. These systems, which have been in use for over 30 years, are increasingly managed by less experienced personnel as seasoned SCADA engineers retire. This knowledge gap only amplifies the cybersecurity risks associated with legacy systems.
Cyber Threats Facing Industrial Automation
The cyberattacks targeting industrial automation in recent years have grown in complexity and frequency. In 2024, attacks disrupted automated assembly lines, held companies ransom with malware, and exposed sensitive data on connected IT networks.
Key threats to industrial automation include:
- Unprotected OT Systems: When OT systems lack real-time cybersecurity protections, they become an easy entry point for hackers.
- Data Breaches: Interconnected IT and OT networks create vulnerabilities that attackers can exploit to steal sensitive data.
- Ransomware: Cybercriminals use ransomware to lock systems and demand payment to restore access, crippling operations.
Solutions to Strengthen Cybersecurity in Industrial Automation
To protect industrial facilities, it’s crucial to adopt cybersecurity measures tailored to the unique needs of OT and IoT systems.
- Retrofit Cybersecurity for OT Devices: Many OT devices lack built-in security. Deploying cybersecurity appliances that encrypt traffic and establish secure tunnels between devices can instantly protect these systems. Manufacturers can also embed software for built-in security in new devices.
- SaaS-Based Cybersecurity Solutions: Tools like DOME offer real-time protection for connected edge devices, including controllers, sensors, cameras, and machines. These solutions detect and stop cyberattacks before they occur, providing easy deployment for new or existing networks.
- Virtual Security Operations Center (vSOC): A vSOC enables continuous monitoring of attempted breaches, providing around-the-clock protection and real-time alerts. This is particularly valuable for small to medium-sized manufacturers with limited budgets and staff.
- Continuous Testing and Monitoring: Regularly assess vulnerabilities in OT and IT systems through penetration testing, system audits, and vulnerability scans.
The Gap Between Large and Small Manufacturers
While larger manufacturers often have the resources to invest in robust cybersecurity programs, smaller and medium-sized manufacturers frequently lag behind. For these entities, starting with a vSOC or affordable cybersecurity solutions can lay the groundwork for greater security.
Bridging this gap is essential, as attackers often target smaller companies with weaker defenses. By taking proactive steps, even smaller manufacturers can protect their operations from cyber threats and position themselves for future success.
Conclusion
The convergence of OT and IT has brought tremendous advancements to industrial automation, but it has also created a dangerous landscape of cybersecurity risks. From protecting SCADA systems to deploying real-time security solutions, manufacturers must act now to safeguard their operations.
Whether you’re a small manufacturer or a large industrial facility, cybersecurity should be a top priority in today’s interconnected world. Start by assessing your vulnerabilities, investing in the right tools, and building a security-first culture within your organization.
At The Saturn Partners, we’re here to help you navigate the complex world of industrial cybersecurity. Contact us today to learn how we can protect your business and secure your operations against evolving threats.