Why your manufacturing operations may be more vulnerable to cyber attacks than you realize

In today’s interconnected industrial landscape, businesses must operate at the highest security levels. However, in manufacturing, cyber threats are often underestimated. In fact, cyber attacks targeting manufacturers are almost inevitable. With increasingly sophisticated attack modes and broadening attack surfaces, robust firewalls and sophisticated monitoring systems aren’t sufficient safeguards.

In this year’s Voice of Our Clients research, which included interviews with 177 manufacturing executives, investing in and strengthening cybersecurity and risk management is among the top five business and IT priorities. Manufacturers can proactively prepare for incidents by understanding their vulnerabilities and taking a holistic and strategic approach to ensure security controls are baked-in, not bolted on.

Understanding the extent of your vulnerabilities

Two primary areas leave companies critically exposed: a lack of awareness and system maintenance.

People are often seen as the weakest link in cybersecurity. However, humans generally desire safe and secure environments, but they must also be aware of the associated risks. The challenge is that we can’t know what we don’t know; it is our blind spots that leave us vulnerable. The most advanced security systems become ineffective if employees fail to recognize and follow basic security protocols. On the other hand, restrictive policies can discourage engagement rather than foster a security-conscious culture.

Mitigating this risk requires continuous education, appointing cybersecurity champions, and conducting phishing simulations that train employees to recognize modern cybercriminal tactics.

System maintenance is another critical weakness, particularly in manufacturing environments where operational technology (OT) systems tend to be outdated. Many OT systems run on legacy platforms that are no longer supported, even though they remain essential for production. Unlike IT systems, which benefit from automated patching and updates, OT environments frequently lack regular maintenance due to concerns about system downtime. The result is a growing attack surface that cybercriminals can exploit.

Best practices for mitigating these risks include devising alternative patching strategies, conducting asset discovery assessments, deploying network segmentation to isolate IT and OT systems, and ensuring real-time monitoring of industrial control systems (ICS) to detect anomalies before they escalate.

Why proactive measures are the need of the hour

Cyberattacks have evolved into a structured and profitable business. Criminal organizations operate as efficiently as legitimate businesses, employing AI-driven tactics to launch sophisticated ransomware and phishing attacks. Many manufacturers assume they are not interesting enough to be targeted, but this is a misconception. Cybercriminals don’t just target high-profile organizations. Instead, they take advantage of weaknesses wherever they find them, whether through targeted extortion or mass phishing campaigns.

Manufacturing plants and OT environments are especially lucrative targets because they rely on uptime and continuity. Threat actors are aware that disruptions to production lines can result in millions of dollars in lost revenue per day, making companies more likely to pay ransoms. Additionally, integrating IT and OT without proper security measures has created new vulnerabilities, allowing attackers to pivot from IT breaches into OT networks, potentially causing physical damage to machinery or triggering production shutdowns.

Insurance companies and regulatory bodies are addressing this growing threat by enforcing stricter compliance measures. New legislation, such as the EU’s NIS2 Directive, is compelling organizations to prioritize cybersecurity—not only within their own operations, but also across their supply chain ecosystems.

Cybersecurity is a business imperative, and since the likelihood of a cyberattack is more real than most people think, it needs to be a board-level priority. Postponing or neglecting to take security measures can lead to severe business disruption and regulatory penalties. The time is now for businesses to achieve compliance and build stronger relationships with customers and across the supply chain.

Beyond data breaches

When organizations consider cyberattacks, they often focus on data breaches or temporary system disruptions. However, the consequences can be much more severe, particularly in industrial settings. Financial costs include ransom payments, investigation expenses, legal fees, regulatory fines, lost productivity, downtime costs, and increased insurance premiums. Operational disruptions involve damaged equipment, production halts, undelivered orders, and potential loss of license to operate. Human and environmental impacts can include employee stress, fatalities, spills, or contamination caused by compromised industrial systems.

Unlike traditional IT breaches, OT cyberattacks can have devastating real-world consequences. A compromised industrial control system (ICS) can lead to machinery malfunctions, safety hazards, or even explosions. For example, at a steel mill in Germany, hackers caused a furnace to overheat, resulting in significant physical damage. Another example is the attack on Maersk in 2017, which disrupted global shipping and cost an estimated $300 million. These incidents highlight that cyber threats extend beyond data breaches—they can endanger lives and cripple entire industries.

Plan for the unexpected with a mindset shift

Planning for the unexpected, even the unthinkable, allows manufacturers to invest in business continuity and protect themselves. Just as companies invest in workplace safety, cybersecurity should be recognized as a core component of operational resilience. A proactive approach to cybersecurity strengthens defenses before an attack occurs, spreads investment costs over time, and supports digital transformation efforts by ensuring new technologies are adopted with security in mind.

Cybersecurity is not a one-time project or solely an IT-only concern—it is an ongoing commitment that requires organizational buy-in at every level. Within manufacturing, prioritizing cybersecurity requires a shift in mindset from viewing it as an expense to recognizing it as a fundamental business enabler that can help you operate with agility and confidence.