What Are Some of the Security Challenges in Smart Manufacturing?

Smart factories face a multitude of security challenges, especially if they are adopting new technologies to be used in combination with legacy hardware. Additionally, in an age of such heightened cybersecurity risk, organizations need to not only protect themselves from current perceived threats but future-proof their systems to allow for evolving measures to be taken as new threat profiles emerge.
Smart factories face a multitude of security challenges, especially if they are adopting new technologies to be used in combination with legacy hardware. Additionally, in an age of such heightened cybersecurity risk, organizations need to not only protect themselves from current perceived threats but future-proof their systems to allow for evolving measures to be taken as new threat profiles emerge.

The internet of things (IoT) has brought about a colossal change in the extent to which technological connectivity features in our everyday lives.

Furthermore, the industrial internet of things (IIoT) has fundamentally altered traditional manufacturing processes, bringing about exciting change, coupled with broad new security challenges. 

The benefits of a smart factory are significant to operational efficiency. Supply chain management, predictive maintenance, and accessibility to real-time monitoring are just a few examples.

Integrated manufacturing software with sophisticated IIoT systems only further enhances the visibility and control that smart factories can have over all facets of their operation.

That said, adapting to smart factory technologies is an expensive exercise, and ensuring that sufficient security measures are taken to protect that investment is crucial.

Threat scenarios

Smart factory organizations must be aware of potential attack scenarios to improve the quality and effectiveness of their security.

Common IIoT cyberattack methods include:

Exploited vulnerabilities

  • Smart factory systems are typically connected to many devices and equipment via a single network. This means that any attack on one of those devices could exploit the vulnerability of the entire system. 

  • Smart factories must also address the convergence between IT and physical securities and the transition from closed to connected cyber-physical security systems.

  • Typically, industrial systems have not been designed to handle cybersecurity breaches, and the resulting vulnerabilities must be recognized and addressed for maximum protection. 

Malware deployment

  • Historically, malware deployment is the most common approach hackers take in cyber attacks.

  • In 2018, hackers were found to be using cryptocurrency-mining malware to launch a cyber attack on a European water facility

  • Many different kinds of malware are used in cyber attacks, including ransomware, spyware, and trojans. Hackers also plan their malware deployment according to what method may be the most undetectable or create the most damage.

  • As a result, smart factory securities must be prepared for techniques such as spear-phishing and watering hole attacks, social engineering, and more. 

(See how with Sophos Intercept X combines ransomware protection, deep learning malware detection, exploit prevention, EDR, and more in a single solution, from New Competitor in the 2022 ‘ASTORS’ Homeland Security Awards Program Sophos. Learn more at: www.sophos.com/Intercept-X. Courtesy of Sophos and YouTube.)

Man-in-the-Middle (MitM) attacks

  • Smart factory systems rely on various communication channels to facilitate operations.

  • With MitM attacks, hackers can infiltrate these communication channels, resulting in the vulnerability of critical information, or the hacker inputting their own data to interrupt processes.

  • Therefore, ensuring that a system’s internal communication channels are secure is critical to overall security.

Denial-of-service (DoS) attacks

  • The goal of a DoS attack is to shut down or otherwise disable a device or network.

  • A distributed DoS (DDoS) attack is a type of DoS attack that uses a botnet (a group of compromised devices) to attack the system’s processor.

  • A DoS or DDoS attack ultimately seeks to shut down a network or machine and render it inaccessible to authorized users.

  • This is achieved by sending the target information to trigger a crash, or simply flooding it with traffic. 

Device hacking

  • It only takes one device within a network to be hacked to compromise the security of the entire system. With physical access, hackers can use the device to send incorrect information to the network, potentially affecting the whole production line.

  • Even without physical access, hackers can use the device to spread malware throughout the network. 

A full ‘chain of trust’ for software and data management must be created within a smart manufacturing system, and all potential vulnerabilities must be carefully considered and addressed.
A full ‘chain of trust’ for software and data management must be created within a smart manufacturing system, and all potential vulnerabilities must be carefully considered and addressed.

Areas of security challenges

As well as becoming familiar with the possible cyberattack methods, smart factory managers must carefully consider where their operation’s security challenges lie.

Some of the most common ones include:

Updating legacy hardware

  • A significant complication that factories face when adopting new IIoT technologies is integrating them with legacy hardware.

  • When new systems are built onto existing legacy systems, unidentifiable vulnerabilities and outdated security measures may inhibit optimal protection. 

Supply chain vulnerabilities

  • A product manufacturing company’s supply chain can be complex, often relying on a variety of third parties.

  • Therefore, fragmented supply chain channels must be carefully managed to ensure maximum product security.

Human error

  • Any organization that adopts new technologies must consider the heightened system vulnerabilities caused by new users.

  • Therefore, it is essential that all factory workers be sufficiently trained and educated as to the risks associated with gathering and handling sensitive data to best prevent an attack. 

Security updates

  • Traditional update processes are typically not available to individual users of IoT networks, making security updates particularly challenging.

  • In addition, in OT (operational technology) environments, operations such as security updates must be performed during downtime hours, thus requiring careful planning. 

Unused function gateways

  • Many industrial machines are designed to offer a far larger number of functions than is often utilized.

  • Consequently, access to unused functions within machines can significantly broaden the potential for cyberattacks.

Final thoughts

Smart factories face a multitude of security challenges, especially if they are adopting new technologies to be used in combination with legacy hardware.

(Learn More. To help organizations realize the future of manufacturing, Deloitte teamed up with an ecosystem of renowned solution providers and technology innovators to create The Smart Factory @ Wichita experience. Courtesy of Deloitte US and YouTube.)

Additionally, in an age of such heightened cybersecurity risk, organizations need to not only protect themselves from current perceived threats but future-proof their systems to allow for evolving measures to be taken as new threat profiles emerge.

A full ‘chain of trust’ for software and data management must be created within a smart manufacturing system, and all potential vulnerabilities must be carefully considered and addressed. 

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2021 ‘ASTORS’ Awards Luncheon (starting front row, left to right) SIMS Software President & CEO Michael Struttmann; TENEO Risk Advisory Executive Chairman Commissioner Bill Bratton; NEC National Security Systems President Dr. Kathleen Kiernan; TSA Administrator David Pekoske; Fortior Solutions General Counsel Katherine Cowan; NEC Corporation of America Senior Vice President & Chief Experience Officer Raffie Beroukhim; TENEO Risk Advisory Chief of Staff David Cagno; Infragard National Board Member Doug Farber, Lumina Analytics Co-Founder & Chairman Allan Martin, and AMAROK Senior Vice President Sales & Marketing Mike Dorrington.
2021 ‘ASTORS’ Awards Luncheon (starting front row, left to right) SIMS Software President & CEO Michael Struttmann; TENEO Risk Advisory Executive Chairman Commissioner Bill Bratton; NEC National Security Systems President Dr. Kathleen Kiernan; TSA Administrator David Pekoske; Fortior Solutions General Counsel Katherine Cowan; NEC Corporation of America Senior Vice President & Chief Experience Officer Raffie Beroukhim; TENEO Risk Advisory Chief of Staff David Cagno; Infragard National Board Member Doug Farber, Lumina Analytics Co-Founder & Chairman Allan Martin, and AMAROK Senior Vice President Sales & Marketing Mike Dorrington.

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Thomas Richardson, FDNY Chief of Department; Dr. Kathleen Kiernan, President of NEC National Security Systems; and Richard Blatus, FDNY Assistant Chief of Operations at the 2021 ‘ASTORS’ Awards Luncheon at ISC East.

AST Honors Thomas Richardson, FDNY Chief of Department; Dr. Kathleen Kiernan, President of NEC National Security Systems; and Richard Blatus, FDNY Assistant Chief of Operations, at the 2021 ‘ASTORS’ Awards Luncheon at ISC East.

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TSA Administrator David Pekoske addressing attendees at the 2021 ‘ASTORS’ Awards Luncheon in New York City on November 17, 2021. (Be sure to see AST Exclusive Interview, facilitated by Dr. Kathleen Kiernan HERE.)

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American Security Today’s Annual ‘ASTORS’ Awards is the preeminent U.S. Homeland Security Awards Program, and now in its Seventh Year, continues to recognize industry leaders of Physical and Border Security, Cybersecurity, Emergency Preparedness – Management and Response, Law Enforcement, First Responders, as well as federal, state and municipal government agencies in the acknowledgment of their outstanding efforts to Keep our Nation Secure.

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