Manufacturing companies now face more cyberattacks than any other industry, surpassing even finance and healthcare sectors.
As factories become increasingly connected through Industrial Internet of Things (IIoT) devices and automated systems, they create new pathways for cybercriminals to exploit. Ransomware attacks, data theft, and supply chain breaches now target both digital assets and physical manufacturing operations.
A single security breach can shut down entire production lines, throw delivery schedules into chaos, and generate millions in lost revenue during downtime. Attackers also steal proprietary designs and trade secrets, putting years of research and development work at risk and threatening competitive positioning. These growing threats make cybersecurity for manufacturing a fundamental component of modern factory operations.
This article explains the main cyber risks manufacturers face, the best practices for securing operational technology (OT) and IT systems, and the frameworks that guide industrial cybersecurity programs. It also explores how SentinelOne’s manufacturing solutions help protect connected environments with AI-driven detection and response across endpoints, OT networks, and IoT devices.
What is Cybersecurity in Manufacturing?
Cybersecurity in manufacturing involves protecting digital systems, connected machines, and industrial networks that keep production running smoothly.
This includes securing areas such as:
- Information technology (IT) systems, including servers, databases, and enterprise tools.
- Operational technology (OT) systems, including programmable logic controllers (PLCs) and other control equipment.
- Supervisory control and data acquisition (SCADA) systems monitor and manage industrial processes.
- Connected devices and Industrial Internet of Things (IIoT) assets that link production lines with enterprise networks.
- Supply chain and third-party software that integrate into factory operations.
Manufacturing cybersecurity focuses on preventing disruptions, data theft, and sabotage that could halt operations or damage equipment.
It builds resilience across critical environments to maintain uptime, protect intellectual property, and reduce cyberattack-related safety and financial risks.
Why Cybersecurity Is Important for Manufacturing
Manufacturing has become the top target for ransomware and data breaches worldwide. Attackers focus on this sector because operational uptime and intellectual property carry significant financial value.
When production systems stop, losses can reach millions of dollars per hour, affecting output, delivery schedules, and supplier relationships. Stolen design files or proprietary process data can also give competitors or hostile actors an advantage, causing long-term damage beyond the immediate incident.
The convergence of IT and OT systems has widened the attack surface. Connected equipment, industrial IoT devices, and cloud-based management tools now link production floors with enterprise networks. While this integration supports automation and data-driven efficiency, it also increases the number of potential entry points for threat actors. Once attackers gain access, they can move laterally between systems and disrupt entire operations.
In a highly connected environment shaped by Industry 4.0, downtime equals lost revenue and reputational harm. Preventing attacks and responding quickly when incidents occur are now core parts of manufacturing resilience. Cybersecurity has become as important to factory operations as safety and quality control, forming the foundation for stable, uninterrupted production.
Key Cybersecurity Risks in Manufacturing
The rise of smart factories, connected machinery, and cloud-based production systems has introduced new manufacturing cyber risks. Understanding them is critical for building stronger, more resilient manufacturing cybersecurity defenses.
Ransomware & Operational Disruption
Ransomware is one of the most disruptive threats to manufacturing. Attacks can halt production lines, disable control systems, and ripple across global supply chains. The Sophos State of Ransomware in Manufacturing and Production 2024 report found that 65% of manufacturers were hit by ransomware, leading to costly downtime and lost output.
With every hour of disruption translating into major financial loss, some manufacturers feel pressured to pay ransoms to resume operations. However, payment does not guarantee recovery or data safety, making strong prevention and recovery strategies essential.
Legacy Systems & Unpatched OT
Many manufacturing plants still depend on legacy programmable logic controllers (PLCs) and outdated operating systems that were never built for modern cybersecurity needs. These systems manage essential processes but often lack ongoing vendor support or patch availability.
In operational environments, even small updates can interrupt production, so maintenance is often delayed. As a result, unpatched devices and supposedly isolated, air-gapped systems remain exposed, giving attackers potential entry points into critical operations.
IoT & IIoT Vulnerabilities
The rapid growth of smart sensors and connected machinery has improved visibility and automation in manufacturing, but it has also widened the attack surface.
Many IoT and IIoT devices lack strong security controls such as authentication and encryption. When compromised, these devices can be used as entry points to infiltrate or disrupt production systems, including industrial controllers and enterprise networks.
Network segmentation, continuous monitoring, and strict access controls are critical to limit the risk from connected devices.
Supply Chain Attacks
Modern manufacturing relies on a wide network of suppliers, maintenance providers, and logistics partners. Cybercriminals often exploit these connections by targeting smaller vendors with weaker defenses.
Once a third-party system is compromised, attackers can move through trusted connections to reach larger manufacturers.
In several cases, breaches have started with infected maintenance or logistics software, spreading malware across multiple facilities and disrupting production on a large scale.
For example, in November 2024, the ransomware group Termite claimed responsibility for a breach at Blue Yonder, which provides warehouse management systems (WMS) and supply chain software services. The breach caused delays in warehouse operations, disrupted scheduling, and affected shipping-and-delivery workflows for companies that depend on Blue Yonder’s software.
In early 2023, semiconductor equipment manufacturer MKS Instruments also suffered a ransomware attack. Since MKS supplies critical industrial equipment and services, the attack delayed shipments and production across the supply chain, costing the company $200 million in lost revenue.
Human Error & Insider Risks
Human error remains one of the leading causes of cybersecurity incidents in manufacturing. Phishing emails, weak credentials, and accidental system misconfigurations often open the door to larger attacks.
The risk extends beyond administrative staff to engineers and technicians who manage production systems. Regular security awareness training and phishing simulations help reduce mistakes, while strong access controls limit the impact of insider actions.
To build stronger human-layer defenses, manufacturers can follow awareness and response strategies outlined in the SentinelOne Manufacturing Whitepaper.
Nation-State & Industrial Espionage
State-sponsored attackers seeking a competitive or strategic advantage target manufacturing intellectual property and trade secrets.
These groups often focus on stealing blueprints and research data from advanced sectors such as automotive, aerospace, medicine, and semiconductors. The goal is to replicate innovations or weaken competitors.
Key Frameworks & Standards for Manufacturing Cybersecurity
Building a strong cybersecurity foundation in manufacturing requires alignment with proven frameworks and compliance standards. These guidelines help organizations manage cyber risk, protect sensitive data, and strengthen resilience across both IT and OT environments.
NIST Cybersecurity Framework (CSF)
The NIST Cybersecurity Framework (CSF) provides a structured model for improving cybersecurity maturity in manufacturing. It defines five core functions: Identify, Protect, Detect, Respond, and Recover, which guide organizations through risk management and incident response.
The Manufacturing Profile (NISTIR 8183) adapts these principles to address the unique combination of IT and OT systems found in factories, helping manufacturers improve visibility and align with recognized best practices.
NIST SP 800-82
NIST Special Publication 800-82 is the primary reference for securing Industrial Control Systems (ICS). It offers detailed recommendations for protecting Supervisory Control and Data Acquisition (SCADA) systems, Programmable Logic Controllers (PLCs), Distributed Control Systems (DCS), and other automation components that manage industrial processes.
Applying its guidance helps strengthen manufacturing cybersecurity by reducing risks from remote access misuse and network-based attacks across production systems.
ISA/IEC 62443
The ISA/IEC 62443 series is the international standard for industrial automation and control system security. It covers people, processes, and technology within OT environments, addressing areas such as secure system design and incident handling.
Following this framework helps organizations establish consistent security practices and improve collaboration between IT and OT teams to maintain operational integrity.
Best Practices for Securing Manufacturing Systems
Segment IT and OT Networks
Manufacturers should maintain a clear separation between corporate IT networks and operational technology (OT) or ICS environments. Network segmentation limits lateral movement if an attacker gains access and helps contain breaches before they affect production lines or critical equipment.
Secure Legacy and OT Devices
Many factories still depend on older systems that are difficult to replace. Implementing endpoint protection compatible with legacy operating systems helps detect unusual activity and block malicious behavior. Changing default credentials and limiting remote access also reduces exposure to common attack methods.
Adopt a Zero Trust Model
A Zero Trust model operates on the principle that no device or user is automatically trusted. This approach strengthens defenses by enforcing least privilege access, multi-factor authentication (MFA), and frequent credential reviews. It reduces the risk of unauthorized access and limits the impact of compromised accounts.
Implement Strong Access Controls & MFA
Every user should have a unique account and follow strong password practices. Applying least privilege access prevents unnecessary permissions. For sensitive production or control systems, use Privileged Access Management (PAM) tools to monitor and manage administrative access securely.
Conduct Regular Vulnerability Assessments
Routine vulnerability scans and penetration tests should cover both IT and OT environments. Identifying and addressing weak points before attackers find them helps reduce the likelihood of successful intrusions or operational disruptions.
Establish an Incident Response Plan
Manufacturers need a cybersecurity incident response plan that reflects their operational processes. Conducting tabletop exercises with both security and production teams tests preparedness and helps minimize downtime during real incidents.
Employee Training & Awareness
A strong security culture starts with awareness. Regular employee training and phishing simulations help staff recognize suspicious activity and respond appropriately. This proactive approach lowers the risk of human error and strengthens the organization’s overall defense posture.
Trends in Manufacturing Cybersecurity
The manufacturing sector is undergoing rapid change in its approach to cybersecurity. Below are several key trends shaping the industry today:
AI-Driven Protection
More manufacturers are deploying AI and machine learning (ML) to identify anomalies and threats in real time across both IT and OT systems.
61% of cybersecurity professionals plan to adopt AI/ML within 12 months in the manufacturing sector.
Convergence of IT and OT Security
As IT and OT systems merge, the potential points of attack increase. A 2024 study reported that 80% of manufacturers experienced an increase in security incidents with IT and OT integration.
Integrating OT into enterprise security programs is a priority for maintaining holistic protection.
Rising Cyber Attacks on Manufacturing
Cyberattacks targeting manufacturers continue to rise in scale and impact. Recent analysis shows manufacturing as the most vulnerable sector, with cyber risk scores 11.7% below the global average.
Attacks in this industry occur 60% more often and are 20% more severe than in other sectors.
To combat this, manufacturers are strengthening IT and OT defenses, sharpening incident response, and adopting proactive controls to protect production and IP.
Incident Costs and Threat Complexity
Attacks on manufacturers are both rising and getting costlier. Between 2018 and October 2024, more than 850 manufacturing firms were hit by ransomware. Each incident cost an average of about $1.9 million in daily downtime losses. This resulted in roughly $17 billion in total damages across the industry.
Manufacturers should expect this trend to continue as threat actors target high-value production environments. Setting up rapid detection systems, reliable data backups, tested recovery plans, and continuous network monitoring is important to mitigating the financial and operational impact of future attacks.
Cyber Readiness and Workforce Skill Gaps
Cyber readiness is emerging as a top workforce trend in manufacturing cybersecurity. 53% of companies with revenues above $30 billion rated cybersecurity practices and standards as extremely important skill sets.
However, many manufacturers face shortages in cybersecurity talent.
To close this gap, companies are investing in workforce training, upskilling programs, and partnerships with cybersecurity service providers.
Building a culture of cyber awareness at every level, from plant operators and maintenance teams to IT administrators, is also becoming essential.
How SentinelOne Helps Manufacturers Protect OT & IT Environments
In the era of Industry 4.0, manufacturing has become the most targeted industry for cyber incidents, accounting for over 32% of all reported attacks. With the average cost of a data breach reaching $4.88 million, and backdoors being the primary method of entry for adversaries, manufacturers require a security posture that prioritizes both high-availability and autonomous response.
The SentinelOne Singularity™ Platform delivers AI-driven protection designed to keep production lines running and intellectual property safe across IT and OT systems.
Autonomous Threat Detection and Response
Production environments require a "safety-first" response that stops threats before they can disrupt sensitive machinery. SentinelOne’s behavioral AI operates autonomously, allowing agents to detect and contain ransomware in real-time even on air-gapped networks or systems without a cloud connection. For manufacturers relying on vintage shop-floor equipment, the platform provides unmatched support for 17 years of Windows (including EOL versions like XP and 7) and 10 major Linux distributions. If a threat is detected, patented 1-Click Rollback can instantly restore files to their pre-infected state, eliminating the need for manual re-imaging and drastically reducing mean time to repair.
Frictionless OT and IoT Visibility
Securing the modern factory requires full visibility into the convergence of IT and OT, yet many environments remain riddled with "shadow" devices and unmanaged assets. SentinelOne Network Discovery (formerly Ranger®) solves this by turning every managed endpoint into a passive network sensor, discovering and fingerprinting everything from PLCs and HMIs to smart sensors without requiring additional hardware or network changes. This allows security teams to instantly build asset inventories and quantify exposure to hardware-vulnerabilities like Ripple20, ensuring no rogue device can serve as a lateral entry point into the production cell.
Unified XDR and Proactive Intelligence
As IT and OT networks become increasingly interconnected, security silos create critical vulnerabilities. Singularity™ XDR breaks these barriers by correlating telemetry across endpoints, cloud workloads, and identities into a single, contextualized Storyline™. This enables security teams to respond at machine speed to advanced persistent threats targeting the supply chain. By integrating Purple AI, analysts can use natural language to hunt for emerging risks, while curated threat intelligence helps prioritize high-risk events. This unified approach not only protects uptime and intellectual property but also lowers the total cost of ownership by consolidating multiple security tools into a single, efficient agent.
From automotive assembly lines to semiconductor fabrication facilities, SentinelOne’s Singularity™ Platform empowers manufacturers with autonomous, real-time cybersecurity that protects both IT and OT environments, supports complex industrial operations, and preserves uptime and data integrity.
FAQs
Cybersecurity is vital in manufacturing because modern production systems depend on connected machines, software, and data exchange across global supply chains. A successful cyberattack can stop operations, damage equipment, or expose sensitive information such as product designs and supplier details.
Protecting both IT and OT environments helps manufacturers maintain uptime, safety, and trust with customers and partners.
Manufacturers face a mix of threats that target both digital and physical systems. The most common include ransomware, phishing, supply chain attacks, insider threats, and malware that targets ICS. Ransomware is particularly damaging because it can lock down production systems and disrupt operations for days or weeks.
To secure OT systems, manufacturers should separate OT and IT networks, monitor all connected devices, and apply regular software and firmware updates. Using strong authentication, network segmentation, and continuous threat detection can reduce exposure. Partnering with cybersecurity vendors that offer visibility across both IT and OT environments also helps detect and contain attacks early.
Several frameworks guide cybersecurity practices in manufacturing. The NIST Cybersecurity Framework (CSF) provides a broad structure for managing risk. NIST SP 800-82 focuses specifically on industrial control systems, while the ISA/IEC 62443 series offers standards for securing automation and control systems. These frameworks help organizations assess vulnerabilities and apply consistent controls across plants and suppliers.
Key steps include maintaining regular data backups, controlling access to sensitive systems, and training employees to recognize phishing attempts. Using endpoint detection and response (EDR) tools and restricting administrative privileges can also help block ransomware from spreading. Continuous monitoring and incident response planning are vital to limit downtime if an attack occurs.
