Produce Safely. Operate Securely.
PROTECTING MANUFACTURING OPERATIONS
We help manufacturers secure production environments, protect intellectual property, and maintain operational continuity through comprehensive OT cyber security aligned with IEC 62443 standards.
"Manufacturing organizations face the challenge of securing increasingly connected production environments while protecting proprietary processes, maintaining quality standards, and ensuring worker safety in the face of evolving cyber threats."
Manufacturing Cyber Security Challenges
Productivity, Quality and Safety are the foundational pillars of manufacturing operations.
Modern manufacturing relies on interconnected automation systems including PLCs, SCADA, robotics, and MES platforms to achieve production targets and quality specifications. These systems control everything from raw material handling to finished product packaging, operating 24/7 to maximize output and minimize downtime.
Industry 4.0 initiatives have accelerated connectivity between production systems and enterprise networks, enabling real-time analytics, predictive maintenance, and remote monitoring. However, this connectivity also exposes manufacturing OT to cyber threats that can halt production, compromise product quality, or endanger worker safety.
With intellectual property theft, ransomware attacks, and supply chain compromises targeting manufacturers, implementing IEC 62443-compliant security controls is essential to protect operations and competitive advantage.
Manufacturing Threat Landscape
Current Threat Environment
- Ransomware attacks targeting production facilities, forcing complete shutdowns costing millions per day
- Intellectual property theft through compromised engineering workstations and historian databases
- Supply chain attacks embedding malware in equipment firmware and software updates
- Nation-state espionage targeting advanced manufacturing capabilities and trade secrets
- Insider threats from disgruntled employees or contractors with system access
- Unpatched vulnerabilities in legacy manufacturing equipment and control systems
Business Impact
- Production downtime directly impacts revenue - hours of lost production can cost hundreds of thousands to millions
- Quality deviations from cyber incidents can result in product recalls, liability, and brand damage
- Safety system compromises put workers at risk and trigger regulatory investigations
- Loss of proprietary formulas, processes, and designs undermines competitive position
- Customer audits and supply chain security requirements mandate demonstrable cybersecurity controls
- Regulatory compliance (IEC 62443, NIS2, industry-specific standards) increasingly required for market access
Manufacturing Systems We Secure
Production Control
PLCs, distributed control systems (DCS), SCADA supervisory systems, and industrial PC-based controllers managing production processes.
Robotics & Automation
Industrial robots, automated guided vehicles (AGVs), collaborative robots (cobots), and machine vision systems for inspection and quality control.
MES/MOM Systems
Manufacturing execution systems, manufacturing operations management platforms, and production scheduling systems bridging OT and IT.
Safety Systems
Safety PLCs, emergency stop systems, light curtains, safety relays, and machine guarding systems protecting workers.
Quality & Testing
Laboratory information management systems (LIMS), coordinate measuring machines (CMM), and automated testing equipment.
Asset Management
Computerized maintenance management systems (CMMS), condition monitoring platforms, and predictive maintenance analytics.
Manufacturing Risk Management Strategy
IEC 62443-Aligned Approach
For manufacturers building cyber security programs, OTFIELD provides structured implementation of IEC 62443 industrial automation and control systems security standards - the globally recognized framework for manufacturing OT security.
We begin by understanding your production environment's criticality - which processes cannot afford downtime, which systems contain intellectual property, and where safety systems protect workers. This operational context drives security zone design, risk assessment, and control selection.
Structured Security Implementation
Phase 1: Zone & Conduit Design
Objective: Segment manufacturing network into security zones based on criticality and risk
- Identify production assets and group by criticality, function, and security requirements
- Define security zones (e.g., safety zone, production control zone, enterprise zone)
- Document conduits (data flows) between zones and external systems
- Assess current network architecture against IEC 62443 zone model
- Identify assets requiring high availability and those with safety functions
- Map intellectual property locations (recipes, formulas, processes)
This foundation enables targeted security investments aligned with business and safety priorities.
Phase 2: Security Level Assessment & Implementation
Objective: Achieve target security levels per IEC 62443-3-3 for each zone
Framework Components:
- IEC 62443-2-1 - Security program requirements for asset owners
- IEC 62443-3-2 - Security risk assessment for system design
- IEC 62443-3-3 - System security requirements and security levels
- IEC 62443-4-2 - Technical security requirements for components
- ISO/IEC 27001/27002 - Information security management system
Core Security Controls:
- Network segmentation and industrial firewalls between zones
- Access control - authentication, authorization, and privilege management
- System integrity - application whitelisting, change detection, patch management
- Data confidentiality - encryption for sensitive data and communications
- Data flow restriction - allow-listing and protocol filtering at conduits
- Event logging and security monitoring for anomaly detection
- Backup and recovery procedures for production systems
- Removable media controls and USB device management
- Vendor and remote access security (secure VPN, jump hosts, MFA)
Securing Industry 4.0 Initiatives
Digital transformation and smart manufacturing require security-by-design approaches:
Cloud & Edge Computing
- Secure cloud connectivity for analytics and remote monitoring
- Edge computing device security and management
- API security for cloud-to-OT integrations
- Data governance for production data in cloud environments
IoT & Connected Devices
- Industrial IoT sensor security and authentication
- Wireless network security (WiFi, Bluetooth, cellular)
- Asset tracking and monitoring system security
- Firmware integrity and update management
Operational Success Factors
Manufacturing organizations must address these critical considerations:
- Can we implement security controls without disrupting 24/7 production schedules?
- How do we secure legacy equipment that cannot be patched or upgraded?
- Do we have visibility into all OT assets, including shadow IT and undocumented systems?
- Can our current team manage OT security alongside production support responsibilities?
- Are our equipment vendors and integrators capable of meeting IEC 62443 requirements?
- How do we balance worker productivity with secure access controls?
Successful manufacturing OT security requires understanding production realities and implementing practical, sustainable controls.
Standards & Compliance Framework
- IEC 62443 - Industrial automation and control systems security (globally recognized standard)
- NIST CSF - Cybersecurity Framework for critical infrastructure
- ISO/IEC 27001 - Information security management system requirements
- NIS2 Directive - EU cybersecurity requirements for medium and large manufacturers
- TISAX - Automotive industry security assessment (for automotive supply chain)
Protect Production. Secure Intellectual Property.
Manufacturing in today's connected environment without robust OT cyber security puts production, quality, and worker safety at risk. Discover how we help manufacturers implement IEC 62443-compliant security that supports operational excellence.
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