Industry 4.0 and the rise of smart factories promise unprecedented benefits in efficiency, productivity and innovation. But, this increasing reliance on connected systems and technologies has a pernicious downside: significantly higher exposure to cyber risks.Traditional manufacturing environments have typically maintained a clear separation between Information Technology (IT) systems, responsible for enterprise functions, and Operational Technology (OT) systems, which control physical equipment and production processes. But this separation is rapidly dissolving. Driven by the need for real-time data, remote monitoring, and enhanced automation, the convergence of OT and IT introduces new and complex security challenges for manufacturers.Legacy OT environments were not designed with cybersecurity best practices in mind and often run on outdated infrastructure and insecure protocols, making them prime targets for cyberattacks. Recent years have seen numerous examples1 of the devastating impact of cyberattacks on manufacturing:Large automotive plants were forced to halt production due to compromised Industrial Control Systems (ICS)2.Critical suppliers had to freeze operations3, disrupting entire supply chains.Organizations have experienced significant losses of private designs and intellectual property4.The question remains - in an increasingly interconnected world, how can manufacturers secure their operations and shield their most valuable assets? Building a Stronger Defense: Zero Trust Redefines Cybersecurity for Manufacturing In a zero trust model, trust is no longer assumed—it’s earned. Based on the principle of "never trust, always verify," this approach scrutinizes every connection, whether it’s a legacy machine with outdated software or a remote technician accessing critical systems.For manufacturers navigating a complex landscape of aging technology, interconnected networks, and escalating internal and external threats, zero trust provides more than just protection—it redefines how security should function in a modern factory. By limiting access to only what’s absolutely necessary, this model not only fortifies defenses but ensures continuous production amidst today’s relentless cyber onslaughts.To help manufacturers embrace a more resilient security strategy, we’ve outlined four critical steps that empower organizations to defend against advanced threats while staying agile and operational.Step 1: Assess and reduce the attack surfaceThe foundation of cyber resilience starts with uncovering the weak links in your security framework. Identify every entry point into your manufacturing environment, expose vulnerabilities, and confront the risks of a potential cyberattack head-on. To effectively reduce your attack surface, start by pinpointing specific areas of risk within your manufacturing environment. These include:Legacy IT and OT systems with known vulnerabilities.Industrial robots and control systems that may be running outdated operating systems.Factory networks utilizing insecure protocols.Connected devices and sensors across your production floor.Upstream supply chain partners with varying levels of security maturity.Downstream distributors and customers who may have network integrations.Remote access points for employees, contractors, and vendors.Next, take steps to reduce your exposure.Conduct a comprehensive risk assessment of both your IT and OT environments to identify vulnerable points and potential attack vectors.Provide secure access to applications without exposing them to the internet with Zscaler Private Access (ZPA).Implement device segmentation strategies that logically separate areas of your environment, such as production, development, and third-party access networks to limit the impact of a security breach. Step 2: Protect operational technology (OT) The combination of limited built-in security and increased connectivity from Industry 4.0 leaves OT systems highly exposed to cyber threats. Legacy network architectures are ill-equipped to protect these environments, as outdated infrastructure, unpatched systems, and open protocols are common vulnerabilities.Zero trust transforms OT security by redefining access and communication within the network. Instead of assuming safety within the perimeter, zero trust treats every user, device, and connection—whether it’s a factory operator, a sensor, or communication between OT devices—as potentially untrusted, ensuring stricter control and reduced risk.Action steps: Leverage identity-based access controls to strictly monitor and authorize all communication attempts within your OT environment. Use robust authentication methods and ensure that only authorized personnel and devices can interact with specific parts of your OT environment.Incorporate segmentation strategies to isolate vulnerable systems and prevent the spread of attacks. By logically dividing your OT environment into smaller, isolated segments, you can drastically limit the potential damage if a breach does occur. Strengthen communication pathways by utilizing encrypted and secure channels, ensuring data integrity without compromising security. Leverage solutions that enable encrypted, real-time communication across your distributed manufacturing plants and supply chain systems, helping to prevent eavesdropping and tampering with critical operational data and transactions. Step 3: Secure remote and contractor accessTraditionally, organizations have relied on VPNs to provide secure connectivity for 3rd parties such as remote employees or contractors, yet this outdated approach introduces serious vulnerabilities. VPNs often provide unrestricted access, allowing compromised users to navigate laterally within the network, turning a minor breach into a widespread incident that can disrupt critical operations.Zero trust offers a more secure solution by verifying every user and device while enforcing least-privileged access. This approach ensures individuals can only access the specific applications and resources they need to perform their tasks and nothing more. By isolating users from the broader network and reducing exposure, manufacturers can take advantage of greater resilience against cyber threats while maintaining seamless and secure operational workflows.Action steps: Replace outdated VPNs with a zero trust solution that eliminates broad network access for remote users and third parties and securely connect them directly to the specific applications they require.Establish and continuously enforce granular, identity-based, least-privilege access policies for all remote users and contractors, defining precisely what resources they can access based on their roles and responsibilities. Implement continuous monitoring and logging of all remote access activity to detect anomalies, safeguard sensitive data, and protect critical systems from potential threats. Step 4: Minimize downtime and maximize supply chain securityYour supply chain is only as strong as its weakest link—a breach at a supplier, distributor, or logistics partner can create a domino effect that impacts your entire operation. With increasingly interconnected supply chains, even the smallest vulnerability can have outsized consequences, disrupting operations and leaving your organization exposed to financial losses and reputational harm.Zscaler empowers manufacturers to address supply chain disruptions and cyber risks with secure connectivity and granular access controls. With advanced threat detection, real-time monitoring, and risk isolation, Zscaler helps protect critical operations and build a resilient, secure infrastructure for today’s interconnected landscape.Action steps:Apply segmentation to separate your systems from your supply chain partners to prevent a breach in a partner's network from spreading to your environment.Gain visibility into supply chain transactions and monitor for potentially malicious transactions occurring within supply chain SaaS applications.Collaborate with supply chain partners to establish resilience-focused security frameworks and encourage the adoption of strong cybersecurity practices across your ecosystem.Implement dynamic risk management to continuously assess risk and adjust access policies to minimize the potential for downtime caused by attacks. The Path Forward: Moving Toward a Secure and Resilient FutureWith advanced cyber threats relentlessly targeting both IT and OT systems, manufacturers relying on outdated security approaches risk compromising their critical assets, disrupting operations, and threatening their future.Modern security isn’t optional—it’s essential. Robust solutions not only minimize costly downtime but also shield sensitive data and protect intellectual property from devastating attacks. Now is the time for manufacturers to break free from the limitations of legacy systems, reduce complexity, cut costs, and unlock new levels of operational efficiency.Don’t wait for a cyberattack to expose your vulnerabilities. Schedule a demo today to see how modern cloud security can fortify your defenses, transform your operations, and secure your path to long-term resilience. 1Inside the Breach: Why & How Manufacturers are Compromised. Process Unity, June 2023, https://www.processunity.com/resources/blogs/inside-the-breach-why-and-how-manufacturers-are-compromised/2Lyon, Peter. Cyber Attack at Honda Stops Production After WannaCry Worm Strikes. Forbes, June 2017,https://www.forbes.com/sites/peterlyon/2017/06/22/cyber-attack-at-honda-stops-production-after-wannacry-worm-strikes/3Toyota Faces Potential Cyberattack Disrupting Global Production. Keepnet, Jan. 2024, https://keepnetlabs.com/blog/toyota-is-shutting-down-its-14-plants-in-japan4Throwback Attack: Visser Precision suffers a DoppelPaymer ransomware attack. Control Engineering, Aug. 2021, https://www.controleng.com/throwback-attack-visser-precision-suffers-a-doppelpaymer-ransomware-attack/
