Insight: How safe are your manufacturing operations? Essential steps to combat cyber threats

In an era when industries are rapidly adopting digital solutions to optimise operations, operational technology (OT) Cyber Security has never been more important. With the convergence of IT and OT systems, manufacturing, energy, and other industrial sectors are increasingly exposed to cyber threats that can disrupt operations, compromise sensitive data, and cause significant financial losses. James Glover from ITI Group explores the importance of building a robust security program and outlines key steps to protect your manufacturing operations against the growing threat of cyber-attacks.

The growing need for OT Cyber Security

The manufacturing industry is susceptible to attacks and attempted breaches due to several reasons, including:

• A rise in connected devices and organisations, with an estimated 29 billion devices expected to be connected by 2030.
• Complex global supply chains, which can enable attacks to spread between organisations.
• Legacy systems that often have vulnerabilities and security gaps.
• Industrial IoT devices that serve as potential targets for cyber-attacks by threat actors.

Research indicates that, for the third consecutive year, the manufacturing sector remains the top target for cyber-attacks, accounting for approximately 25% of incidents. Ransomware is a significant factor, involved in 71% of these cases. Also, the frequency of cyber-attacks on the sector is reportedly rising at an alarming rate of 125% per year.

Historically, OT systems operated in isolated environments, separate from traditional IT networks. This isolated approach provided a degree of security. However, with the rise of Industry 4.0, OT systems are now interconnected with IT systems to enable advanced data analytics, predictive maintenance, and real-time monitoring. While this connectivity delivers significant operational benefits, it also opens the door to cyber threats that were previously unheard of in industrial environments.

The realisation of this vulnerability often comes after high-profile incidents, such as ransomware attacks or breaches targeting critical infrastructure. The consequences can be devastating, from halting production lines to causing environmental hazards or endangering lives. The risks are too great to ignore the need for robust Cyber Security measures in the OT domain.

Establishing a solid IT infrastructure

A secure and resilient IT infrastructure is the foundation of any effective OT Cyber Security strategy. This includes network segmentation, access control, regular patch management and real-time monitoring tools to detect and respond to unusual behaviour that may indicate a cyber threat. Without a solid IT infrastructure, organisations may struggle to protect their operations from increasingly sophisticated cyberattacks.

How to strengthen OT Cyber Security

To protect against the growing threat of cyberattacks, organisations should consider the following steps:

1 – Conduct a risk assessment: Identify critical assets, vulnerabilities, and potential threat vectors in both IT and OT environments.

2 – Develop a comprehensive Cyber Security policy: Define procedures and best practices for mitigating risks and responding to incidents.

3 – Invest in OT-specific security tools: Use solutions tailored for industrial environments, such as intrusion detection systems and endpoint protection for legacy systems.

4 – Employee training and awareness: Equip teams with the knowledge to recognise and respond to Cyber Security threats.

5 – Collaborate with industry partners: Share insights and strategies to stay ahead of emerging threats.

The importance of being proactive

The cost of implementing OT Cyber Security measures is insignificant in comparison to the potential impact of a cyberattack. Proactively addressing vulnerabilities not only safeguards operations but also instils confidence among stakeholders, including customers, partners, and regulators. Organisations that prioritise Cyber Security are better positioned to navigate the complexities of the digital age, turning potential threats into opportunities for innovation, resilience and improved digital maturity.

OT Cyber Security – a lifecycle approach

Industrial Cyber Security is no longer a “nice-to-have” but a critical element of modern operational strategy. By investing in solid IT infrastructure, fostering a culture of security awareness, and implementing robust Cyber Security measures, organisations can protect their operations from the evolving threat landscape. In doing so, they ensure continuity, maintain reputations, and create a solid foundation for sustained digital transformation.

Take the next step in securing your operations

ITI Group collaborates with manufacturers to assess the current position in their security journey and provide tailored support to develop a robust security program. Our approach ensures alignment with the latest standards and industry best practices.

You can learn more about ITI Group’s OT Cyber Security solutions here: Industrial Cyber Security