IEEE ComSoc Technology Blog

By Omkar Ashok Bhalekar with Ajay Lotan Thakur

Introduction

With the advent of new industry 5.0 standards and ongoing advancements in the field of Industry 4.0, the manufacturing landscape is facing a revolutionary challenge which not only demands sustainable use of environmental resources but also compels us to make constant changes in industrial security postures to tackle modern threats. Technologies such as Internet of Things (IoT) in Manufacturing, Private 4G/5G, Cloud-hosted applications, Edge-computing, and Real-time streaming telemetry are effectively fueling smart factories and making them more productive.

Although this evolution facilitates industrial automation, innovation and high productivity, it also greatly makes the exposure footprint more vulnerable for cyberattacks. Industrial Cybersecurity is quintessential for mission critical manufacturing operations; it is a key cornerstone to safeguard factories and avoid major downtimes.

With the rapid amalgamation of IT and OT (Operational Technology), a hack or a data breach can cause operational disruptions like line down situations, halt in production lines, theft or loss of critical data, and huge financial damage to an organization.

Industrial Networking

Why does Modern Manufacturing demand Cybersecurity? Below outlines a few reasons why cybersecurity is essential in modern manufacturing:

• Convergence of IT and OT: Industrial control systems (ICS) which used to be isolated or air-gapped are now all inter-connected and hence vulnerable to breaches.
• Enlarged Attack Surface: Every device or component in the factory which is on the network is susceptible to threats and attacks.
• Financial Loss: Cyberattacks such as WannaCry or targeted BSOD Blue Screen of Death (BSOD) can cost millions of dollars per minute and result in complete shutdown of operations.
• Disruptions in Logistics Network: Supply chain can be greatly disarrayed due to hacks or cyberattacks causing essential parts shortage.
• Legislative Compliance: Strict laws and regulations such as CISA, NIST, and ISA/IEC 62443 are proving crucial and mandating frameworks to safeguard industries

It is important to understand and adapt to the changing trends in the cybersecurity domain, especially when there are several significant factors at risk. Historically, it has been observed that mankind always has had some lessons learned from their past mistakes while not only advances at fast pace, but the risks from external threats would limit us from making advancements without taking cognizance.

This attitude of adaptability or malleability needs to become an integral part of the mindset and practices in cybersecurity spheres and should not be limited to just industrial security. Such practices can scale across other technological fields. Moreover, securing industries does not just mean physical security, but it also opens avenues for cybersecurity experts to learn and innovate in the field of applications and software such as Manufacturing Execution System (MES) which are crucial for critical operations.

Greatest Cyberattacks in Manufacturing of all times:

Familiarizing and acknowledging different categories of attacks and their scales which have historically hampered the manufacturing domain is pivotal. In this section we would highlight some of the Real-World cybersecurity incidents.

Ransomware (Colonial Pipeline, WannaCry, y.2021):

These attacks brought the US east coast to a standstill due to extreme shortage of fuel and gasoline after hacking employee credentials.

Cause: The root cause for this was compromised VPN account credentials. An VPN account which wasn’t used for a long time and lacked Multi-factor Authentication (MFA) was breached and the credentials were part of a password leak on dark web. The Ransomware group “Darkside” exploited this entry point to gain access to Colonial Pipeline’s IT systems. They did not initially penetrate operational technology systems. However, the interdependence of IT and OT systems caused operational impacts. Once inside, attackers escalated privileges and exfiltrated 100 GB of data within 2 hours. Ransomware was deployed to encrypt critical business systems. Colonial Pipeline proactively shut down the pipeline fearing lateral movement into OT networks.

Effect: The pipeline, which supplies nearly 45% of the fuel to the U.S. East Coast, was shut down for 6 days. Mass fuel shortages occurred across several U.S. states, leading to public panic and fuel hoarding. Colonial Pipeline paid $4.4 million ransom. Later, approximately $2.3 million was recovered by the FBI. Led to a Presidential Executive Order on Cybersecurity and heightened regulations around critical infrastructure cybersecurity. Exposed how business IT network vulnerabilities can lead to real-world critical infrastructure impacts, even without OT being directly targeted.

Industrial Sabotage (Stuxnet, y.2009):

This unprecedented and novel software worm was able to hijack an entire critical facility and sabotage all the machines rendering them defunct.

Cause: Nation-state-developed malware specifically targeting Industrial Control Systems (ICS), with an unprecedented level of sophistication. Stuxnet was developed jointly by the U.S. (NSA) and Israel (Unit 8200) under operation “Olympic Games”. The target was Iran’s uranium enrichment program at Natanz Nuclear Facility. The worm was introduced via USB drives (air-gapped network). Exploited four zero-day vulnerabilities in Windows systems at that time, unprecedented. Specifically targeted Siemens Step7 software running on Windows, which controls Siemens S7-300 PLCs. Stuxnet would identify systems controlling centrifuges used for uranium enrichment. Reprogrammed the PLCs to intermittently change the rotational speed of centrifuges, causing mechanical stress and failure, while reporting normal operations to operators. Used rootkits for both Windows and PLC-level to remain stealthy.

Effect: Destroyed approximately 1,000 IR-1 centrifuges (~10% of Iran’s nuclear capability). Set back Iran’s nuclear program by 1-2 years. Introduced a new era of cyberwarfare, where malware caused physical destruction. Raised global awareness about the vulnerabilities in industrial control systems (ICS). Iran responded by accelerating its cyber capabilities, forming the Iranian Cyber Army. ICS/SCADA security became a top global priority, especially in energy and defense sectors.

Upgrade spoofing (SolarWinds Orion Supply chain Attack, y.2020):

Attackers injected malicious pieces of software into the software updates which infected millions of users.

Cause: Compromise of the SolarWinds build environment leading to a supply chain attack. Attackers known as Russian Cozy Bear, linked to Russia’s foreign intelligence agency, gained access to SolarWinds’ development pipeline. Malicious code was inserted into Orion Platform updates, released between March to June 2020 Customers who downloaded the update installed malware known as SUNBURST. Attackers compromised SolarWinds build infrastructure. It created a backdoor in Orion’s signed DLLs. Over 18,000 customers were potentially affected, including 100 high-value targets. After the exploit, attackers used manual lateral movement, privilege escalation, and custom C2 (command-and-control) infrastructure to exfiltrate data.

Effect: Breach included major U.S. government agencies: DHS, DoE, DoJ, Treasury, State Department, and more. Affected top corporations: Cisco, Intel, Microsoft, FireEye, and others FireEye discovered the breach after noticing unusual two-factor authentication activity. Exposed critical supply chain vulnerabilities and demonstrated how a single point of compromise could lead to nationwide espionage. Promoted the creation of Cybersecurity Executive Order 14028, Zero Trust mandates, and widespread adoption of Software Bill of Materials (SBOM) practices.

Spywares (Pegasus, y.2016-2021):

Cause: Zero-click and zero-day exploits leveraged by NSO Group’s Pegasus spyware, sold to governments. Pegasus can infect phones without any user interaction also known as zero-click exploits. It acquires malicious access to WhatsApp, iMessage or browsers like Safari’s vulnerabilities on iOS, including zero-days attacks on Android devices. Delivered via SMS, WhatsApp messages, or silent push notifications. Once installed, it provides complete surveillance capability such as access to microphones, camera, GPS, calls, photos, texts, and encrypted apps. Zero-click iOS exploit ForcedEntry allows complete compromise of an iPhone. Malware is extremely stealthy, often removing itself after execution. Bypassed Apple’s BlastDoor sandbox and Android’s hardened security modules.

Effect: Used by multiple governments to surveil activists, journalists, lawyers, opposition leaders, even heads of state. The 2021 Pegasus Project, led by Amnesty International and Forbidden Stories, revealed a leaked list of 50,000 potential targets. Phones of high-profile individuals including international journalists, associates, specifically French president, and Indian opposition figures were allegedly targeted which triggered legal and political fallout. NSO Group was blacklisted by the U.S. Department of Commerce. Apple filed a lawsuit against NSO Group in 2021. Renewed debates over the ethics and regulation of commercial spyware.

Other common types of attacks:

Phishing and Smishing: These attacks send out links or emails that appear to be legitimate but are crafted by bad actors for financial means or identity theft.

Social Engineering: Shoulder surfing though sounds funny; it’s the tale of time where the most expert security personnel have been outsmarted and faced data or credential leaks. Rather than relying on technical vulnerabilities, this attack targets human psychology to gain access or break into systems. The attacker manipulates people into revealing confidential information using techniques such as Reconnaissance, Engagement, Baiting or offering Quid pro quo services.

Security Runbook for Manufacturing Industries:

To ensure ongoing enhancements to industrial security postures and preserve critical manufacturing operations, following are 11 security procedures and tactics which will ensure 360-degree protection based on established frameworks:

A. Incident Handling Tactics (First Line of Defense) Team should continuously improve incident response with the help of documentation and response apps. Co-ordination between teams, communications root, cause analysis and reference documentation are the key to successful Incident response.

B. Zero Trust Principles (Trust but verify) Use strong security device management tools to ensure all end devices are in compliance such as trusted certificates, NAC, and enforcement policies. Regular and random checks on users’ official data patterns and assign role-based policy limiting full access to critical resources.

C. Secure Communication and Data Protection Use endpoint or cloud-based security session with IPSec VPN tunnels to make sure all traffic can be controlled and monitored. All user data must be encrypted using data protection and recovery software such as BitLocker.

D. Secure IT Infrastructure Hardening of network equipment such switches, routers, WAPs with dot1x, port-security and EAP-TLS or PEAP. Implement edge-based monitoring solutions to detect anomalies and redundant network infrastructure to ensure least MTTR.

E. Physical Security Locks, badge readers or biometric systems for all critical rooms and network cabinets are a must. A security operations room (SOC) can help monitor internal thefts or sabotage incidents.

F. North-South and East-West Traffic Isolation Safety traffic and external traffic can be rate limited using Firewalls or edge compute devices. 100% isolation is a good wishful thought, but measures need to be taken to constantly monitor any security punch-holes.

G. Industrial Hardware for Industrial applications Use appropriate Industrial grade IP67 or IP68 rated network equipment to avoid breakdowns due to environmental factors. Localized industrial firewalls can provide desired granularity on the edge thereby skipping the need to follow Purdue model.

H. Next-Generation Firewalls with Application-Level Visibility Incorporate Stateful Application Aware Firewalls, which can help provide more control over zones and policies and differentiate application’s behavioral characteristics. Deploy Tools which can perform deep packet inspection and function as platforms for Intrusion prevention (IPS/IDS).

I. Threat and Traffic Analyzer Tools such as network traffic analyzers can help achieve network Layer1-Layer7 security monitoring by detecting and responding to malicious traffic patterns. Self-healing networks with automation and monitoring tools which can detect traffic anomalies and rectify the network incompliance.

J. Information security and Software management Companies must maintain a repo of trust certificates, software and releases and keep pushing regular patches for critical bugs. Keep a constant track of release notes and CVEs (Common Vulnerabilities and exposures) for all vendor software.

K. Idiot-Proofing (How to NOT get Hacked) Regular training to employees and familiarizing them with cyber-attacks and jargons like CryptoJacking or HoneyNets can help create awareness. Encourage and provide a platform for employees or workers to voice their opinions and resolve their queries regarding security threats.

Current Industry Perspective and Software Response

In response to the escalating tide of cyberattacks in manufacturing, from the Triton malware striking industrial safety controls to LockerGoga shutting down production at Norsk Hydro, there has been a sea change in how the software industry is facilitating operational resilience. Security companies are combining cutting-edge threat detection with ICS/SCADA systems, delivering purpose-designed solutions like zero-trust network access, behavior-based anomaly detection, and encrypted machine-to-machine communications. Companies such as Siemens and Claroty are leading the way, bringing security by design rather than an afterthought. A prime example is Dragos OT-specific threat intelligence and incident response solutions, which have become the focal point in the fight against nation-state attacks and ransomware operations against critical infrastructure.

Bridging the Divide between IT and OT: Two way street

With the intensification of OT and IT convergence, perimeter-based defense is no longer sufficient. Manufacturers are embracing emerging strategies such as Cybersecurity Mesh Architecture (CSMA) and applying IT-centric philosophies such as DevSecOps within the OT environment to foster secure by default deployment habits. The trend also brings attention to IEC 62443 conformity as well as NIST based risk assessment frameworks catering to manufacturing. Legacy PLCs having been networked and exposed to internet-borne threats, companies are embracing micro-segmentation, secure remote access, and real-time monitoring solutions that unify security across both environments. Learn how Schneider Electric is empowering manufacturers to securely link IT/OT systems with scalable cybersecurity programs.

Conclusion

In a nutshell, Modern manufacturing, contrary to the past, is not just about quick input and quick output systems which can scale and be productive, but it is an ecosystem, where cybersecurity and manufacturing harmonize and just like healthcare system is considered critical to humans, modern factories are considered quintessential to manufacturing. So many experiences with cyberattacks on critical infrastructure such as pipelines, nuclear plants, power-grids over the past 30 years not only warrant world’s attention but also calls to action the need to devise regulatory standards which must be followed by each and every entity in manufacturing.

As mankind keeps making progress and sprinting towards the next industrial revolution, it’s an absolute exigency to emphasize making Industrial Cybersecurity a keystone in building upcoming critical manufacturing facilities and building a strong foundation for operational excellency. Now is the right time to buy into the trend of Industrial security, sure enough the leaders who choose to be “Cyberfacturers” will survive to tell the tale, and the rest may just serve as stark reminders of what happens when pace outperforms security.

References

• https://www.cisa.gov/topics/industrial-control-systems
• https://www.nist.gov/cyberframework
• https://www.isa.org/standards-and-publications/isa-standards/isa-standards-committees/isa99
• https://www.cisa.gov/news-events/news/attack-colonial-pipeline-what-weve-learned-what-weve-done-over-past-two-years
• https://www.law.georgetown.edu/environmental-law-review/blog/cybersecurity-policy-responses-to-the-colonial-pipeline-ransomware-attack/
• https://www.hbs.edu/faculty/Pages/item.aspx?num=63756
• https://spectrum.ieee.org/the-real-story-of-stuxnet
• https://www.washingtonpost.com/world/national-security/stuxnet-was-work-of-us-and-israeli-experts-officials-say/2012/06/01/gJQAlnEy6U_story.html
• https://www.kaspersky.com/resource-center/definitions/what-is-stuxnet
• https://www.malwarebytes.com/stuxnet
• https://www.zscaler.com/resources/security-terms-glossary/what-is-the-solarwinds-cyberattack
• https://www.gao.gov/blog/solarwinds-cyberattack-demands-significant-federal-and-private-sector-response-infographic
• https://www.rapid7.com/blog/post/2020/12/14/solarwinds-sunburst-backdoor-supply-chain-attack-what-you-need-to-know/
• https://www.fortinet.com/resources/cyberglossary/solarwinds-cyber-attack
• https://www.amnesty.org/en/latest/research/2021/07/forensic-methodology-report-how-to-catch-nso-groups-pegasus/
• https://citizenlab.ca/2023/04/nso-groups-pegasus-spyware-returns-in-2022/
• https://thehackernews.com/2023/04/nso-group-used-3-zero-click-iphone.html
• https://www.securityweek.com/google-says-nso-pegasus-zero-click-most-technically-sophisticated-exploit-ever-seen/
• https://www.nist.gov/itl/smallbusinesscyber/guidance-topic/phishing
• https://www.blumira.com/blog/social-engineering-the-human-element-in-cybersecurity
• https://www.nist.gov/cyberframework
• https://www.dragos.com/cyber-threat-intelligence/
• https://mesh.security/security/what-is-csma/
• https://download.schneider-electric.com/files?p_Doc_Ref=IT_OT&p_enDocType=User+guide&p_File_Name=998-20244304_Schneider+Electric+Cybersecurity+White+Paper.pdf
• https://insanecyber.com/understanding-the-differences-in-ot-cybersecurity-standards-nist-csf-vs-62443/
• https://blog.se.com/sustainability/2021/04/13/it-ot-convergence-in-the-new-world-of-digital-industries/

About Author:

Omkar Bhalekar is a senior network engineer and technology enthusiast specializing in Data center architecture, Manufacturing infrastructure, and Sustainable solutions with extensive experience in designing resilient industrial networks and building smart factories and AI data centers with scalable networks. He is also the author of the Book Autonomous and Predictive Networks: The future of Networking in the Age of AI and co-author of Quantum Ops – Bridging Quantum Computing & IT Operations. Omkar writes to simplify complex technical topics for engineers, researchers, and industry leaders.