The Hidden Security Gaps In Manufacturing: A Case Study On Risk Acceptance Gone Wrong

Manufacturers are rapidly embracing digital operations, yet many still depend on outdated risk assessments, which can lead to critical vulnerabilities remaining unchecked. I've been in manufacturing cybersecurity long enough to know one thing: most company leaders think they're safe – until they're not.

Consider the case of a global manufacturing organization that believed it had a strong handle on cybersecurity when, in reality, half of the facility's critical systems were operating with significant security vulnerabilities. This critical gap surfaced not because of a new threat, but because of risks the organization had deemed "acceptable" years ago.

This approach to cybersecurity risk management is all too common in manufacturing. Old, seemingly harmless risks that your team "accepted" years ago—and then promptly forgot about—could be a ticking time bomb sitting right under your nose.

On paper, this manufacturer appeared to have everything right.

Imagine driving a car and never checking the oil or the tires after the first inspection. Sounds crazy, right? But that's exactly what many manufacturers are doing with their technology. This oversight created a "set-it-and-forget-it" approach to risk management that exposed critical operational technology (OT) systems to evolving cyber threats.

Manufacturing isn't like other industries. You're not just managing computer networks – you're dealing with a complex ecosystem where business systems meet factory floor technology. It’s a delicate balance of information technology (IT) and operational technology (OT). Your robotic arms, temperature controls, and assembly line systems weren't originally designed with cybersecurity in mind, creating inherent vulnerabilities. These are legacy systems trying to survive in a hyper-connected digital world.

When these systems connect to IT networks—often necessary for modern digital manufacturing—they create an expanded attack surface that cybercriminals are eager to exploit. If attackers breach these systems, the consequences are immediate and severe—production lines grind to a halt, quality control systems fail, and an entire operation can be shut down within minutes—creating ripple effects throughout your entire supply chain.

Consider a ransomware attack targeting one of these unprotected OT systems. Years ago, when the risk was initially "accepted," ransomware might have been a minor concern. Today, with manufacturing becoming a prime target for cybercriminals, such an attack could devastate operations and result in millions in losses.

Recent history proves this isn't hypothetical. In 2021, Foxconn, a massive electronics manufacturer supplying tech giants like Apple and Google, faced a single ransomware attack that cost them over $100 million in estimated losses. How? Through a simple social engineering trick that was able to exploit vulnerable systems and encrypt files and data. Exactly the kind of evolving threat that outdated risk assessments fail to address.

How can manufacturing security teams fight back? Organizations can protect themselves by implementing five critical strategies:

As manufacturing continues its digital transformation, a proactive and adaptive cybersecurity strategy is essential. Organizations must evolve their approach to risk management from a static, one-time assessment to a dynamic, continuous process that acknowledges human vulnerabilities and the changing threat landscape.

The manufacturers who will be standing strong five years from now aren't the ones with the most expensive technology. They're the ones who treat cybersecurity as a critical part of their business strategy, not just another checkbox.