Why Cybersecurity Should Be Part of Every Automation Strategy

Advances in automation over the past decade have certainly made manufacturing and supply more efficient and improved output quality. With IT and OT working closer together than ever to streamline processes, however, a new variety of cyber risks arises.

The biggest downside to digital transformation through automation and IT/OT convergence is that attack surfaces increase in size, particularly thanks to IoT devices that are increasingly targeted by hackers.

The business impacts of ignoring cybersecurity when rolling out automation can be colossal. Loss of data through device hacking can lead to reputational damage and compliance reprimands. There’s downtime to expect, too, if malicious attacks bring systems to their knees.

However, with proactivity, it’s possible to integrate cybersecurity into your automation strategy.

When Control Systems Go Online, So Do the Threats

OT control systems that are suddenly connected to a wealth of IoT devices or to the broader internet are in for a sharp shock. Simply plunging a previously isolated control system into complex automation and interconnectivity means it’s at serious risk from sophisticated cyberattacks such as malware, ransomware, and phishing, threats that increasingly target vulnerable IoT and OT devices.

OT device exposure to malware is growing, year on year, at an alarming rate of around 12%. That means critical systems are often at the mercy of the online wilds without a firm cybersecurity strategy.

Some exposed legacy systems may never have been designed to go online or even connect to other devices. Consider, for example, the Colonial Pipeline ransomware attack of 2021, which resulted in a State of Emergency, putting millions of fuel transport at serious risk. The event reportedly unfolded because exposed systems lacked multi-factor authentication.

Ultimately, firms have a responsibility to fortify their systems, the data they hold, and the processes they run, in line with the modern cyber threat landscape. Much like how companies that process card data should follow PCI standards, firms establishing automated environments should take measured steps to close the security gap and protect every potential ingress.

Where Vulnerabilities Hide in Modern Automation Infrastructures

To take measured steps, firms need to understand the potential vulnerabilities hiding behind the benefits of automation and interconnectivity.

Weaknesses vary from case to case, but typical inroads for hackers and malware may include:

Exposed legacy hardware or software lacking built-in security
Neglected cybersecurity training and human errors
Poor access control standards
Zero network segmentation
Shadow IT/OT (where new, unsecure devices and elements are sneaked into infrastructure without vetting)
Poor vendor security
Insecure industrial endpoints (i.e., those systems completely new to going online)

Crucially, every element of an automation setup must be accounted for from a cybersecurity perspective. Frustratingly, research finds that there is still no full consensus on how to address IT and OT security concerns in a single approach.

Therefore, plant operators using automation should integrate cybersecurity into all projects from the get-go.

Integrating Cybersecurity into Automation Projects from Day One

Benefits aside, any firms designing and rolling out automation projects should carefully account for cyber risk at every potential point of ingress and egress. If legacy systems have to be included, are there ways that they can be patched, or can they be safely retired after a set point?

What are some of the potential dangers for endpoints and IoT devices, for example, if certain security measures aren’t applied at implementation? Consider a zero-tolerance approach to risk – no matter how unlikely they are, it’s vital to account for every eventuality.

Integrating cybersecurity at day one also means getting buy-in from all stakeholders, employees, and those at each critical point in the chain of accountability. It’s important to set clear expectations, to budget carefully, and to create threat models to prove the potential for risk.

Starting cybersecurity with a “day one” approach doesn’t mean dismantling everything and starting again. It may simply mean investing more carefully at new automation solutions that are proven to integrate with your existing systems and processes!

Incident Response in Industrial Environments: What's Different?

Taking all of the above into account, it’s also wise to think carefully about the new, unique risks that industrial OT, upgraded with IoT and online accessibility, pose.

As part of drawing up an effective new incident response plan, you need to consider:

Which OT elements in your setup are likely to pose a physical or safety threat if hackers were to shut them down
Vendor dependencies and their cybersecurity approaches (are your manufacturers and suppliers of industrial equipment necessarily going to have a proactive approach to security?)
Potential downtime costs escalating when broader OT is part of the bigger picture (will a simple hack lead to severe manufacturing delays, for example?)
Attack monitoring and analysis challenges with OT (even with IoT reporting in place, can you easily account for the effects that malware may have on your physical systems?)
How you can roll out continuous monitoring for industrial systems, regardless of how they are connected and the roles they play
Fail-safe planning (are there any systems that can shut down, with the help of automation, should a threat be detected?)

There’s also a strong argument to automate industrial cybersecurity with the help of AI. Around a third of industrial firms are considering these options, according to IBM.

Designing Automation That’s Resilient by Default

Although automation systems may be efficient and boost productivity significantly regardless of your industry or operations, that doesn’t mean they are infallible against cyber threats. This is especially true if you are augmenting legacy systems and processes that might not be IoT-ready!

In which case, it pays to think about security as a priority whenever you implement automation into an existing setup. You don’t have to rebuild everything from scratch, but you must consider ways to reduce your attack surface (e.g., through segmenting devices and networks) and to protect your older, but still reliable systems against modern threats.

Otherwise, risks may not be limited to IT alone – health, safety, and compliance issues can all arise from a few simple cybersecurity mistakes.

Author Bio:

Tyler Owen

Vice President of Product Management for Cybersecurity Solutions at VikingCloud

Tyler serves as the Sr. Director of Product Management for Managed Security Services at VikingCloud. His extensive experience encompasses the entire lifecycle of Information Security infrastructure projects, from pre-sales and planning through to implementation, daily maintenance, and management. Tyler's expertise includes overseeing people, processes, policies, budgets, and resources, ensuring comprehensive security measures that protect and enhance IT infrastructures.

Publish Your Article