Prior to IIoT and smart manufacturing, IT managers had limited insights into the location and performance of equipment on the production floor. They could only spot issues when machines quite literally broke down.
This visibility helps predict equipment lifespans and minimize downtime, and allows organizations to lower operating costs while enhancing both safety and security across the factory floor.
How IIoT Architecture Works
IIoT also has its unique architecture that begins with the device layer, where equipment, sensors, actuators and controllers collect raw operational data. That information is passed through the network layer, which transmits it to the internet via secure gateways. Next, the edge or fog computing layer processes and filters the data locally before sending it to the cloud, helping reduce latency and improving responsiveness. Once in the service and application support layer, the data is stored, analyzed, and used to generate alerts and insights. Finally, the application layer puts that information into action, powering smart robotics, predictive maintenance, automation, inventory monitoring and advanced analytics that can help manufacturers optimize production.
READ MORE: How can operational technology assessments help bridge the IoT divide?
Cybersecurity Concerns for the IIoT
In manufacturing, a single compromise can halt operations, degrade performance, cause data loss or trigger costly downtime. In fact, the stakes of IIoT cyber risks can endanger worker safety, potentially leading to injuries, lawsuits and lasting reputational damage. Here are some of the biggest risks to understand:
An expanded attack surface: As more devices connect across the IIoT environment, the network’s attack surface grows, giving cybercriminals multiple entry points. This opens the door to threats such as malware infections, denial-of-service disruptions, on-path intrusions, memory injection exploits, eavesdropping and selective forwarding attacks, among others.
Unencrypted communication: Ninety-eight percent of all IoT device traffic is unencrypted because most smart devices lack the processing power to run complex encryption programs. This makes it easy for cybercriminals to interfere with device communication.
Equipment that lacks built-in security: Many IIoT devices are not built with strong cybersecurity protections. This is especially true for legacy machines that were never designed to connect to modern networks. Without safeguards such as encryption or secure authentication, these devices can become easy targets.
Skills gap: New and experienced employees alike may struggle to adapt to smart manufacturing systems, whether they’re learning to operate new IIoT-enabled equipment or working with retrofitted legacy machines. This skills gap can make it harder for staff to recognize potential threats or respond quickly to suspicious activity.
DISCOVER: Digital transformation can help you optimize manufacturing efforts.
How To Defend Against IIoT Threats
Defending against IIoT threats requires a layered approach that combines technology, processes and people. Manufacturers should segment their networks to limit the spread of attacks, apply strong encryption and authentication for connected devices, and keep software and firmware regularly updated. Partnering with experienced security providers can also help. Here are five tips to help you stay protected.
- Train your employees. Employee training is one of the strongest defenses. When workers know how to spot unusual activity in their systems or equipment, they can address issues fast. Foremen and maintenance managers should also set clear response procedures and practice them regularly, ideally every quarter.
- Establish a segmented network. Divide your IIoT network into smaller, isolated zones, each with its own rules and protections. This segmentation limits the spread of cyberattacks and also improves efficiency and reduces network slowdowns.
- Update software and patch security vulnerabilities. This is especially true for legacy equipment, as updates can fix security flaws, improve system features and strengthen firewalls against new risks. In many cases, these updates can be done remotely through over-the-air software, which is fast, convenient and cost-effective.
- Install an intrusion detection and prevention system. An IDPS can recognize malicious patterns and abnormalities in equipment, endpoints and networks. This means that even in large facilities, an IDPS can spot incoming threats and respond accordingly.
- Secure device communications. Because many smart devices have limited processing power, they need lightweight but reliable methods to send and receive data safely. Pairing communication protocols such as AMQP (Advanced Message Queuing Protocol), MQTT (Message Queuing Telemetry Transport), or CoAP (Constrained Application Protocol) alongside a secure transmission protocol such as Datagram Transport Layer Security (DTLS) or SSL to protect data as it moves between devices. Firewalls, VPNs and compliance controls can also bolster the IIoT.
The IIoT is still maturing, but vendors are starting to add stronger security features to their devices. In the meantime, these proven security tactics can help smart manufacturers stay safe.
