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Role of cybersecurity in smart manufacturing
Articles- Nov 29,24
As smart factories become the backbone of modern manufacturing, ensuring robust cybersecurity has never been more essential. These connected, automated facilities are prime targets for cyberattacks that could compromise data, disrupt operations, and impact productivity. Effective cybersecurity strategies are essential to protect the complex networks and systems that power Industry 4.0, safeguarding not just technology but also the future of India’s manufacturing landscape, says Sanskriti Ramacha
In an era dominated by digital transformation, the manufacturing sector has embraced cutting-edge technologies such as the Internet of Things (IoT), cloud computing, and automation. While these advancements promise unprecedented efficiency and productivity, they also introduce a heightened risk of cyberattacks. A recent Capgemini survey reveals that 73% of reported smart factory cyberattacks occurred within the last 12 months, underscoring the urgency of addressing cybersecurity challenges. The adoption of smart factories, where operational technology (OT) and information technology (IT) converge, presents unique vulnerabilities that demand a robust and proactive cybersecurity approach. This article explores the critical role of cybersecurity in smart manufacturing, examining the risks, challenges, and strategies essential for safeguarding these technologically advanced facilities.
A rising threat landscape
The integration of IoT devices and interconnected supply chains in smart manufacturing expands the attack surface for cybercriminals. A staggering 79% of organisations agree that cyber risks are higher in smart factories compared to traditional factories, highlighting the pressing need for enhanced security measures. IoT devices serve as potential entry points for attackers, exploiting insecure interfaces. Smart manufacturing also relies heavily on interconnected supply chains, which can lead to risks if any part of the chain is compromised. Attackers can manipulate suppliers to gain access to the larger manufacturing network. Furthermore, insider threats pose significant challenges, as employees may inadvertently or maliciously expose systems to risks. Advanced Persistent Threats (APTs) involve prolonged, targeted cyberattacks where attackers gain access to a network and remain undetected for extended periods, severely disrupting strategic operations. Data integrity risks also arise, as cyberattacks jeopardise the reliability of manufacturing data, causing operational chaos.
The cost of cyberattacks
Cyberattacks on smart factories result in severe financial and operational repercussions. Unplanned downtime due to attacks can cost manufacturers up to $2 million for just four hours. Moreover, the heavy industry sector reports the highest attack rate at 51% , further emphasising the need for sector-specific solutions. Operational disruptions can halt production schedules, divert resources, and force organisations to allocate time for incident responses, all of which detract from productivity and innovation. Non-compliance with regulatory standards can result in hefty fines and reputational damage, further compounding the challenges for manufacturers.
Addressing challenges and solutions
Organisations face numerous challenges in fortifying their smart factories against cyber risks. The scarcity of skilled cybersecurity professionals poses another major hurdle, with 57% of organisations reporting a shortage of talent specific to OT and IoT systems. Additionally, 77% of organisations express concerns over non-standard processes for updating OT and IIoT systems, which increase vulnerabilities. The lack of a standardised approach exacerbates these challenges, making smart factories more susceptible to cyberattacks.
To enhance cybersecurity in smart manufacturing, experts recommend establishing robust governance structures. Leading organisations align with international standards such as IEC and NIST, with 93% of leaders adhering to these protocols. Automating OT cyber assessments is another critical measure that improves insights and tracks progress effectively. Developing specialised teams focused on OT and IIoT threats is also essential; 89% of industry leaders are already investing in such teams to address sector-specific risks. Proactive risk assessments help organisations identify and mitigate vulnerabilities before they impact operations. Enhanced employee training programs can also foster a culture of security awareness, ensuring that teams contribute positively to maintaining secure manufacturing environments.
Framework and regulations
Adhering to established cybersecurity frameworks ensures resilience against evolving threats. The NIST Cybersecurity Framework provides comprehensive guidelines for managing cybersecurity risks in both IT and OT environments. ISO/IEC 27001 is a global standard for information security management systems, offering a systematic approach to managing sensitive company information. IEC 62443 focuses specifically on cybersecurity for industrial automation and control systems, addressing both IT and OT needs. The Cyber Resilience Act (CRA), while primarily focused on the EU context, provides principles that can be influential for Indian manufacturers operating in international markets. Praveen Kulkarni, Director- Security, Risk & Governance, OpenText India, emphasises the importance of such frameworks, noting that they provide systematic approaches to managing cybersecurity challenges while ensuring operational resilience.
Emerging technologies in cybersecurity
Advanced technologies such as blockchain, artificial intelligence (AI), and digital twins are revolutionising cybersecurity in smart manufacturing. AI-driven predictive maintenance proactively identifies and mitigates vulnerabilities in manufacturing equipment. Pankit Desai, Co-Founder & CEO, Sequretek, highlights the role of AI in enhancing cybersecurity capabilities, stating, “AI-powered tools enable faster detection and response, leveraging Gen-AI for incident analysis and prevention.” Companies like CYFIRMA are pioneering the use of external threat landscape management (ETLM) platforms such as DeCYFIR, which provide tailored intelligence and multi-layered insights to help organisations stay ahead of potential threats.
Kumar Ritesh, Founder, CYFIRMA, advocates for collaborative strategies across supply chains to ensure comprehensive protection. He explains that DeCYFIR provides clients with early warnings of impending cyberattacks, enabling them to act quickly to avoid breaches. The platform combines cyber intelligence with attack surface discovery, vulnerability intelligence, and brand intelligence, offering a comprehensive view of the threat landscape.
Sector-specific insights
Certain industries face heightened cybersecurity challenges due to their critical infrastructure and high-value data. Energy, pharmaceuticals, automotive, and aerospace are particularly vulnerable to espionage, sabotage, and operational disruptions. Manish Walia, Head- Industrial Automation, Delta Electronics India, underscores the need for robust firewalls and stringent data protection measures in process industries such as oil & gas and steel. In the automotive sector, Rachit Srivastava, CEO, Mushin Innovation Labs, highlights the criticality of safeguarding sensitive design and manufacturing data. He notes, “A single data breach could jeopardise a company’s reputation and result in substantial losses for customers.” Healthcare institutions also face significant threats, as their reliance on digital health records makes them a target for hackers. These challenges necessitate a proactive and collaborative approach to cybersecurity.
Khushboo Doshi, Managing Director, Rajoo Engineers Ltd., echoes the importance of cybersecurity in today’s interconnected manufacturing environment. She states, “In today’s integrated manufacturing environment, where machines and devices are increasingly connected on the shop floor, cybersecurity has become a critical concern. The risks of cyberattacks and data breaches have grown alongside the adoption of digital technologies, making it imperative for manufacturers to address these challenges with precision and foresight. At Rajoo Engineers, cybersecurity is an integral part of our operations. To safeguard sensitive data and ensure uninterrupted operations, we have established a robust, in-house server infrastructure. Our internal IT team, equipped with specialised expertise, actively monitors and maintains our digital infrastructure to prevent vulnerabilities. Such deliberate measures allow us to secure our data and also maintain the trust of our customers and stakeholders. By prioritising cybersecurity as a fundamental aspect of our manufacturing strategy, we ensure that our operations remain resilient and aligned with the demands of a highly digitalised industry.”
Resilience through collaboration
Effective cybersecurity requires collaboration among all stakeholders, including manufacturers, OEMs, suppliers, and regulatory bodies. Sharing threat intelligence and best practices fosters a unified approach to combating cyber threats. Kumar Ritesh emphasises the importance of multi-party strategies, stating, “A collaborative framework ensures stronger defences and a cohesive response to emerging threats.” Organisations must also work closely with OT vendors to ensure that products are designed with security in mind, incorporating features for real-time monitoring and threat detection. OpenText’s solutions, for instance, focus on ensuring secure data management across interconnected networks of suppliers, manufacturers, and devices. These efforts help build a cohesive cybersecurity framework that addresses the unique challenges of smart manufacturing environments.
The rapid adoption of smart manufacturing technologies brings unparalleled opportunities and unprecedented risks. Cybersecurity is no longer an optional investment but a critical requirement for safeguarding operations, protecting sensitive data, and maintaining business continuity. By adhering to established frameworks, leveraging advanced technologies, and fostering collaboration, manufacturers can build smart systems capable of withstanding ever-evolving cyber threats. As industries embrace the potential of Industry 4.0, robust cybersecurity measures will serve as the foundation for sustainable growth and innovation in the digital age.
Data source: Capgemini
Photo Credit: FREEPIK
cybersecurity
smart manufacturing
manufacturing
IT
threat
security
safety
Rachit Srivastava
Khushboo Doshi
Kumar Ritesh
Praveen Kulkarni
Pankit Desai
Manish Walia
Sanskriti Ramachandran
Capgemini
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