Stronger Manufacturing Cybersecurity: Safeguarding Industry 4.0

How targeted is the manufacturing sector?

Cyber criminals view manufacturing as a lucrative target because a few hours of downtime can cost millions.

Bitsight’s 2025 “State of the Underground” report identified manufacturing as the most targeted industry for the third year in a row, accounting for 22% of the 4,853 documented cyberattacks.

CrowdStrike’s 2025 Global Threat Report found manufacturing is the third most targeted industry for interactive intrusions.

Statista data cited by Fortinet shows the sector endured 638 ransomware attacks in 2023, making it the most victimized industry.

Attackers often leverage phishing emails to steal credentials or deliver malware; over 90% of incidents begin with a phishing message.

Supply chain attacks are another serious issue: Bitsight notes that many assaults start by compromising smaller vendors and partners to gain access to larger manufacturers.

How severe are the consequences?

Cyber incidents have outsized operational and financial impacts on manufacturers.

Unplanned downtime can cost up to $260,000 per hour, according to the research by Aberdeen Strategy & Research, and Deloitte warns that production delays and missed shipments cascade across the global supply chain.

IBM’s research shows the average cost of a cyberattack in the industrial sector is $5.56 million, reflecting data loss, downtime and reputational damage.

Bitsight points out that unplanned downtime accounts for 11% of annual revenue for Fortune 500 firms—about US $1.5 trillion worldwide. Delays in detection compound the problem: manufacturing organizations take an average of 199 days to identify a threat and 73 days to contain it (IBM), longer than the global averages.

These figures illustrate why robust manufacturing cybersecurity is no longer optional.

Why are manufacturers vulnerable?

Manufacturing cybersecurity lags behind other industries for several reasons:

• Legacy systems and OT vulnerabilities: Many factories still run decades‑old industrial control systems that were never designed with cybersecurity in mind. They are difficult to patch, leaving 35% of known vulnerabilities unpatched. OT systems are autonomous and proprietary, unlike IT systems that run standard operating systems; connecting them increases the attack surface.
• IT–OT convergence: Efforts to increase efficiency by linking IT and OT networks introduce new attack vectors. A simple phishing email in the IT environment can propagate malware into production lines.
• Supply chain complexity: Manufacturers rely on a web of suppliers and third‑party vendors. A breach at any partner can compromise sensitive data and disrupt production schedules. Bitsight notes that attackers increasingly exploit these weaker links as initial footholds.
• Lack of cybersecurity awareness: Employees often lack the training to recognize phishing and social engineering attempts; attackers exploit this through deception. Poor access management and insider misuse can also lead to data breaches.
• Rapid digital expansion: The number of connected IoT devices is expected to reach 125 billion by 2030, producing vast amounts of data. Each new sensor, robot or cloud‑based tool adds potential vulnerabilities. Manufacturing saw a 71% surge in threat‑actor activity between 2024 and early 2025, highlighting how attackers are seizing on this expanding attack surface.

Because manufacturing environments combine information technology with physical processes, an effective approach must bridge traditional IT security and industrial control system safety. At Silverback Consulting, we help small manufacturers build comprehensive cybersecurity programs tailored to their unique operational risks. Below are essential components of a strong defense.

1. Perform a Cybersecurity Maturity Assessment

Before designing controls, you need to know where you stand. We will perform maturity assessments to identify gaps. Our experts assess your IT and OT networks, identify vulnerable assets and map dependencies across suppliers and partners. This baseline allows us to prioritize remediation based on risk.

2. Establish Formal Governance

Many operational decisions about OT systems are made on the factory floor with little involvement from IT or security teams. This fragmented approach creates inconsistent security controls. To align IT and OT strategies, Silverback Consulting helps clients develop governance frameworks that assign clear roles and responsibilities, define approval processes for firmware updates and new equipment, and set policies for incident response and reporting.

3. Segment OT and IT Networks

One of the simplest ways to limit lateral movement is network segmentation. Create separate networks for office systems and factory machinery to prevent malware from propagating. We design architectures that isolate production systems, restrict access through firewalls, and employ demilitarized zones (DMZs) between corporate and plant networks. This containment reduces the blast radius of any breach.

4. Implement Multi‑Factor Authentication (MFA)

Compromised credentials are a leading cause of breaches, particularly in manufacturing where remote access is common. Enforcing MFA for all critical systems—especially those controlling production lines—adds a strong layer of defense. Our team deploys user‑friendly MFA solutions that integrate with industrial platforms without disrupting operations.

5. Secure the Software Supply Chain

Open‑source components and third‑party software are integral to modern manufacturing. However, they introduce vulnerabilities if not properly vetted. We at Silverback Consulting audits your software supply chain, verifies code integrity, and monitors for vulnerabilities using threat intelligence feeds. We recommend requiring vendors to meet strict security standards and implementing scanning tools that detect malicious code before deployment.

6. Harden Legacy and IIoT Devices

Manufacturers often run equipment that cannot be patched or updated. To secure these systems, we suggest isolating older machines and monitoring them for anomalies. We help clients deploy intrusion‑prevention software customized for industrial devices, enforce strict access controls, and implement zero‑trust architectures around critical equipment. Additionally, we validate firmware on new machines to ensure it is malware‑free.

7. Map Assets and Conduct Continuous Risk Analysis

Effective risk management starts with a clear inventory of all connected assets. We highlight the importance of mapping OT devices and performing risk‑based analyses to classify high‑risk systems. Our asset management solutions provide real‑time visibility into IT and OT environments, flag outdated systems, and track vulnerabilities. Regular vulnerability scanning and penetration testing keep pace with evolving threats.

8. Train and Empower Your Workforce

The human element remains a leading vulnerability. Many attacks begin with phishing or social engineering. We offer engaging training programs, including gamified simulations, to help employees recognize suspicious emails, use strong passwords and follow security protocols. We also design role‑based training for plant operators and engineers to ensure safe operations without sacrificing productivity.

9. Monitor OT and IT Environments Continuously

Deloitte observed that while 90% of manufacturers report capabilities to detect cyber events, few have extended monitoring into OT environments. Continuous monitoring across IT and OT is crucial to spot anomalies early. Our team implements security information and event management (SIEM) systems with OT‑specific detection rules, combined with endpoint detection and response (EDR) solutions that leverage artificial intelligence to identify abnormal behavior.

10. Develop an Incident Response and Recovery Plan

No defense is flawless. Rapid response can contain damage and reduce downtime. Silverback works with clients to craft and rehearse incident response plans tailored to manufacturing processes. We define escalation paths, coordinate with law enforcement and regulators, and develop communication strategies to minimize reputational harm. We also implement resilient backup systems and disaster recovery solutions to restore operations quickly.

How can manufacturers protect against ransomware and malware?

Ransomware attacks are increasing. Statista reported 6 billion malware attacks in 2023, a 9% rise over the previous year. To combat ransomware, manufacturers need layered defenses: regular backups stored offline, endpoint protection, employee training and a tested incident response plan. Zero‑trust architectures prevent lateral movement, and network segmentation limits the spread of infection. Keeping software and firmware current and using advanced email filtering reduces the risk of initial compromise.

What role does supply chain security play?

Supply chain attacks can cripple operations. Manufacturing’s global supply chains create easy entry points for attackers. Firms must vet the cybersecurity practices of all suppliers, require contractual obligations for security standards and monitor partners continuously. Solutions like our third‑party risk management program evaluate vendor security ratings, track compliance and enforce remediation for weaknesses. Additionally, implementing secure data exchange protocols and multi‑factor authentication for partner access helps safeguard sensitive data.

How can small and mid‑sized manufacturers improve cybersecurity?

Midsize manufacturers are increasingly targeted but often lack the resources of larger firms. Outsourcing security functions to trusted partners like Silverback Consulting provides access to expertise without the cost of an in‑house team.

We offer managed detection and response (MDR) services that monitor networks around the clock, threat intelligence services to stay ahead of adversaries, and virtual Chief Information Security Officer (vCISO) programs that help develop strategy and comply with regulations. These affordable solutions level the playing field.

Is cybersecurity solely an IT problem?

No. Effective manufacturing cybersecurity requires collaboration across IT, OT and executive leadership.

Effective risk management involves IT/OT collaboration and sometimes decisions by local plant managers. Senior leadership must prioritize security investments and enforce governance. OT engineers must coordinate with IT to apply patches and monitor systems.

Human resources and training departments need to cultivate a culture of security awareness. At Silverback, we bring stakeholders together, ensuring that cybersecurity becomes an integral part of operational excellence.

Increasing global regulations emphasize the need for robust cybersecurity practices. Manufacturers handling personal data must comply with GDPR, CCPA or other privacy laws.

The NIST Cybersecurity Framework provides a comprehensive approach for identifying, protecting, detecting, responding and recovering from cyber incidents.

Industry‑specific standards like ISA/IEC 62443 address cybersecurity for industrial automation and control systems.

Many governments are introducing mandatory incident reporting for critical infrastructure, requiring firms to detect and report breaches quickly.

Silverback helps clients interpret and implement these regulations, reducing legal risks and demonstrating due diligence.

Digital transformation will continue to reshape manufacturing. As IoT devices multiply and artificial intelligence becomes embedded in factory systems, the attack surface will expand. Threat actors, including nation‑state groups, are already exploiting these technologies for economic espionage. Preparing for this future requires a proactive, strategic approach.

• Adopt Zero Trust: Assume no user or device is trustworthy by default. Authenticate and authorize every connection, and monitor continuously.
• Invest in AI‑Powered Security: Sophisticated attacks demand advanced detection. AI and machine learning help identify patterns and anomalies faster than human analysts alone.
• Prioritize Collaboration: Share threat intelligence across the supply chain and work with industry consortia and government agencies to stay ahead of emerging threats. Bitsight underscores the importance of public–private collaboration to defend critical infrastructure.
• Embrace Continuous Improvement: Perform regular assessments, simulate incidents and update plans. Cybersecurity is not a one‑time project but an ongoing process.

At Silverback Consulting, we specialize in cybersecurity in manufacturing.

Our team understands the nuances of industrial environments—how downtime affects productivity, how legacy equipment complicates security, and how compliance requirements vary by sector.

We provide end‑to‑end services, from assessments and governance frameworks to managed security operations and incident response. Our risk‑based approach helps prioritize investments where they matter most, ensuring that resources are used effectively to reduce exposure.

Cyber threats will not disappear, and manufacturing will remain a top target because of its economic importance. Investing in manufacturing cybersecurity protects not only your company but also your customers, partners and the broader supply chain. By partnering with Silverback Consulting, you gain expertise, cutting‑edge technology and a commitment to helping you stay ahead of adversaries.

Manufacturing cybersecurity involves safeguarding both information technology (IT) and operational technology (OT) systems—such as industrial control systems, robotics and IoT devices from cyber threats. It’s critical in Industry 4.0 because connected factories are exposed to more entry points for attackers, and nearly half of manufacturers identify operational risks like cyber threats as the greatest danger to smart factory initiatives.

A single breach can halt production lines, delay shipments and damage equipment. Unplanned downtime can cost up to US $260 000 per hour and ripple through supply chains, causing missed deliveries and financial losses.

Attackers see manufacturing as lucrative because it combines high‑value intellectual property with complex supply chains and critical OT systems. Bitsight’s 2025 report notes manufacturing accounts for 22% of documented cyberattacks, and Fortinet reports 638 ransomware attacks on the sector in 2023.

Yes! Manufacturing environments must protect OT systems that control physical processes and often rely on legacy technology. Securing these systems requires specialized controls and governance that go beyond traditional IT security, such as segmenting OT and IT networks and monitoring industrial control devices.

According to Fortinet, the manufacturing sector experienced 638 ransomware attacks in 2023—more than any other industry. Bitsight’s analysis similarly names manufacturing the most targeted industry for cyberattacks overall.

Supply chain attacks are increasingly common because smaller partners often have weaker defenses. Bitsight notes that modern cyberattacks frequently start by infiltrating third‑party vendors or software suppliers, bypassing direct defenses. Manufacturers must assess and monitor the cybersecurity posture of their suppliers to protect their own networks.

The financial impact can be severe. IBM research found the average cost of a cyberattack in manufacturing is US $5.56 million, while unplanned downtime accounts for about 11% of annual revenue for Fortune 500 companies—roughly US $1.5 trillion worldwide.

Production stops immediately, leading to delayed orders and lost revenue. Attackers often demand large payments to restore operations, and downtime can harm relationships with customers and suppliers. Swift incident response and recovery plans are essential to minimize damage.

Manufacturers often take longer than other industries to detect and contain breaches. On average, it takes 199 days to identify a threat and 73 days to contain it. Here at Silverback Consulting, we help reduce these timelines through continuous monitoring and rapid response plans.

Many factories use outdated Industrial Control Systems (ICS) that were never designed with cybersecurity in mind. Approximately 35% of known vulnerabilities in these systems remain unpatched, making them attractive targets for attackers.

Cybercriminals often compromise less‑secure suppliers or maintenance partners to gain indirect access to larger targets. Once inside a vendor’s system, they can pivot into your production network, steal data, or deploy ransomware. Regularly auditing and securing your vendors’ cybersecurity practices helps reduce this risk.

Begin with a cybersecurity maturity assessment that evaluates your IT and OT controls, identifies gaps and prioritizes remediation. We recommend performing such assessments as a first step toward building resilience. Silverback Consulting offers tailored assessments that help manufacturers understand their strengths and weaknesses.

Network segmentation limits an attacker’s ability to move laterally from a compromised office system to a production system. Keeping OT and IT networks separate reduces the risk of malware spreading across your entire facility and is a widely recommended best practice.

Multifactor authentication (MFA) adds a layer of security by requiring users to provide two or more verification factors. In a factory, MFA can be deployed for remote access to control systems or sensitive data, using hardware tokens, mobile apps or biometric devices. It protects against compromised credentials and is part of a comprehensive defense strategy.