Published: April 10, 2026Table of Contents
Executive Summary
Manufacturing has a target on its back. Ransomware groups and nation-state actors are all coming after this sector. Based on my experience providing managed IT services for manufacturers across the Midwest, most organizations aren’t as prepared as they think.
This isn’t a new problem. The manufacturing sector consistently ranks among the most attacked industries globally, and the consequences go far beyond stolen data. We’re talking about halted production lines, missed shipments, and millions in lost revenue.
Here’s a summary on how to improve cybersecurity for manufacturing firms:
- Build full visibility across IT and OT assets
- Identify and prioritize critical production systems
- Segment IT and OT networks to limit attack spread
- Enforce role-based access and enable MFA
- Protect legacy systems with isolation and monitoring
- Implement real-time threat detection and monitoring
- Develop and regularly test incident response plans
- Secure and limit third-party/vendor access
Why Cybersecurity in Manufacturing Is Different
IT vs. OT Cybersecurity
Cybersecurity in manufacturing environments extends beyond traditional IT assets like laptops and email systems. It also includes operational technology such as production equipment, programmable logic controllers (PLCs), and supervisory control and data acquisition (SCADA) systems. Many of these systems were originally designed for reliability and uptime, not with modern cybersecurity requirements in mind.
Traditional IT security focuses on confidentiality, integrity, and availability. In operational technology (OT) environments, the priorities are different: availability and safety come first. If a production system fails or behaves unpredictably, it can create real safety risks.
OT systems often rely on proprietary software, are infrequently patched due to the need to avoid production downtime, and are increasingly connected to IT networks and the internet—expanding their exposure in ways they were not originally designed to handle. I have seen manufacturers where the IT team and the plant engineers barely talk to each other, let alone coordinate on security. That gap is where attackers thrive.
The Cost of Downtime in Manufacturing
The average manufacturer deals with roughly 800 hours of equipment downtime per year. That’s over 15 hours every single week. Unplanned downtime across the industry costs an estimated $50 billion annually.
When a cyberattack affects operational technology environments, the impact can extend beyond individual systems. Incidents such as ransomware can disrupt multiple interconnected assets, potentially halting production across a facility. This can lead to production delays, missed delivery commitments, contractual penalties, and downstream customer impacts. Recovery timelines in these scenarios are often longer than in traditional IT environments, as systems must be carefully restored, validated, and brought back online without compromising safety or product quality.
Top Cyber Risks in Manufacturing
Ransomware on Production Lines
Ransomware is one of the most significant threats facing manufacturers today. Attackers recognize that production downtime creates substantial pressure to pay, and they increasingly target industrial control systems. For example, the EKANS ransomware strain that impacted manufacturers globally in 2020 was designed to target a defined set of industrial control system (ICS) processes, demonstrating the targeted and deliberate nature of these attacks.
Legacy Systems and Unpatched Equipment
Many manufacturing environments still run systems that are 15, 20, sometimes 30 years old. These systems work great for what they were built to do but they were never designed to withstand modern cyber threats, and in many cases they simply cannot be patched without shutting down production. Every unpatched system is an open door.
Third-Party Vulnerabilities
Your supply chain is part of your attack surface. Vendor connections, remote maintenance access, third-party software; each one introduces risk. The Colonial Pipeline attack and the Clorox breach both demonstrated how third-party and supply chain weaknesses can cascade into massive operational disruptions at billion-dollar companies.
Start With Visibility
Asset Inventory Across IT and OT
You can’t protect what you can’t see. That sounds obvious but based on my experience, a shocking number of manufacturers don’t have a complete, accurate inventory of every device on their network — especially on the OT side. Connected sensors, legacy PLCs, IIoT devices that someone installed three years ago and forgot about. They’re all potential entry points.
Start by cataloging everything. Every physical device, every software platform, every connection between IT and OT environments.
Identify Critical Systems
Once you have visibility, prioritize. Not every system carries the same risk. Identify the assets that are most critical to production and to safety, and focus your security efforts there first. Ask yourself: if this system went down tomorrow, what happens to our operations?
Segment and Control Access
Separate IT and OT Networks
If your IT and OT networks are flat, meaning an attacker who compromises a workstation can reach your production systems, you have a serious problem. Network segmentation is one of the most effective steps you can take. Keep IT and OT on separate network segments with strict controls governing traffic between them.
Role-Based Access and MFA
Limit who can access what. Implement role-based access controls so people only have the permissions they actually need, and deploy multi-factor authentication wherever possible, especially for remote access. Remote connections into OT environments are a prime attack vector, and I’ve seen too many manufacturers with wide-open VPN access that any compromised credential can exploit.
Protect What You Can’t Patch
Securing Legacy Systems
Not every system can be updated. That’s the reality of manufacturing. But you can still protect legacy equipment by:
- Isolating it from the broader network
- Monitoring traffic to and from those systems for anomalies
- Implementing application whitelisting so only approved processes can run
- Adding compensating controls like intrusion detection around the segments where legacy systems live
Minimizing Operational Disruption
Security measures that shut down production aren’t going to get buy-in from anyone. Every control you implement needs to account for operational continuity. That means testing changes in non-production environments, scheduling security updates during planned maintenance windows, and working closely with plant engineers — not around them.
Monitor and Respond
Real-Time Threat Detection
You need eyes on your environment around the clock. Advanced detection tools that monitor network traffic, identify anomalous behavior, and generate real-time alerts are no longer optional. Threats move fast. One case study I’ve seen involved malware that was identified within two seconds of execution by AI-driven monitoring before it could spread laterally. That kind of speed is what saves production lines.
Incident Response Planning
Having detection without a response plan is like having a fire alarm but no fire department. Build an incident response plan that covers both IT and OT environments, define clear roles and responsibilities, and practice it. Tabletop exercises, simulations, whatever works for your team — just don’t wait until you’re in the middle of an actual incident to figure out who does what.
Where to Start (Next 90 Days)
If this all feels overwhelming, here’s a practical breakdown for your first 90 days.
Assess Risks (Days 1–30)
- Conduct a thorough asset inventory across IT and OT
- Perform a risk assessment to identify your most critical vulnerabilities
- Evaluate your current network architecture for segmentation gaps
Implement Quick Wins (Days 31–60)
- Enable MFA on all remote access points
- Segment your most critical OT systems from the IT network
- Establish or update your incident response plan
- Review and tighten third-party access controls
Build Monitoring and Response (Days 61–90)
- Deploy network monitoring across IT and OT environments
- Set up alerting for anomalous activity on critical systems
- Run your first incident response tabletop exercise
- Establish a regular cadence for security reviews and patching where possible
Final Thoughts for Manufacturing Executives
The threats to manufacturing aren’t going away. They’re getting worse. But the good news is that meaningful progress doesn’t require a massive budget or a complete overhaul overnight. It requires focus, a clear plan, and the willingness to treat cybersecurity as a business priority, not just an IT problem. Start where you are. Build from there. If you need help building out your cybersecurity program, please let us know. We are here to help.