When you think about cybersecurity, you probably picture hackers targeting office emails or stealing customer data. But in manufacturing, cyber threats don’t just put your data at risk—they can shut down your entire production line.
Your factory floor is full of interconnected machines, PLCs, sensors, and custom control systems—many running legacy software or connected to business networks. These operational technology (OT) systems are vulnerable in ways most traditional IT setups aren’t.
Ignoring these hidden cybersecurity risks can cost you more than just data—it can mean costly downtime, missed deadlines, damaged equipment, and even safety hazards.
The Hidden Cybersecurity Risks Inside Your Factory Walls
Unsegmented Networks Expose Critical OT Systems
Many manufacturers have IT and OT networks running side-by-side—or worse, combined. When your PLCs, SCADA systems, and sensor networks share the same environment as your email servers and file shares, one phishing email or infected USB stick can spread ransomware straight to the machines controlling your production line.
Example: An employee accidentally opens a malicious attachment in an office email. Within hours, your production dashboards and even your CNC machine controllers start locking up. Without network segmentation, malware spreads unchecked, bringing your plant to a halt.
Legacy Equipment Running Unsupported Software
Manufacturing equipment often runs on specialized systems designed years ago, sometimes decades ago. Many of these systems run on unsupported versions of Windows or proprietary operating systems that don’t receive security patches anymore – making them an easy target for attackers. Unlike office PCs, these machines can’t simply be patched overnight without risking downtime or calibration issues.
Example: Your automated welding stations run software from 2010, no longer supported by the vendor. Hackers exploit an old vulnerability, shutting down a production cell during peak demand, costing thousands in lost output and expedited repairs.
Weak Access Controls and Shared Credentials
On the factory floor, it’s common for multiple operators or technicians to share login credentials to access systems quickly. While convenient, this practice makes it impossible to track who did what—and means a compromised credential gives attackers broad access.
Example: A disgruntled former employee still has active credentials. They use their access to introduce malware or sabotage workflows, causing delays and forcing costly audits.
Phishing and Social Engineering Targeting Non-IT Staff
Your frontline workers, operators, and supervisors aren’t typically trained on cybersecurity threats. Attackers know this and often target them with phishing emails disguised as work orders, vendor invoices, or HR notifications.
Example: An operator clicks on a fake vendor invoice link and unknowingly downloads ransomware. Within hours, your entire manufacturing execution system (MES) is encrypted, and you can’t track job status or quality checks.
Insufficient Monitoring and Incident Response
Many manufacturers focus on keeping systems running but don’t have real-time monitoring or rapid incident response plans tailored to their unique environments. Without quick detection, breaches can go unnoticed until they cause significant damage.
Example: Malware silently exfiltrates proprietary manufacturing data and installs backdoors for later attacks—while your IT team is none the wiser. By the time it’s detected, critical intellectual property is compromised.
How to Protect Your Factory from Hidden Cybersecurity Risks
- Segment OT and IT networks: Keep your PLCs, SCADA, and sensor networks isolated from business systems and the internet.
- Update and patch legacy equipment where possible: Work with vendors to secure outdated software or plan phased upgrades.
- Enforce strong access controls: Implement unique credentials, role-based access, and multi-factor authentication, even on the shop floor.
- Train all employees on cybersecurity: Tailor training for operators and non-IT staff to recognize phishing and social engineering.
- Implement continuous monitoring: Use specialized tools to watch OT networks and respond to threats quickly.
Why Manufacturers Choose Aldridge
At Aldridge, we specialize in cybersecurity solutions built for the manufacturing environment. We understand the unique risks posed by your OT systems and deliver tailored solutions that balance security with operational efficiency.
Partner with Aldridge and build an IT and security foundation that keeps your team safe and your business moving.
