Cybersecurity: Importance in Process Manufacturing and Process Automation

Process manufacturing sectors continue to undergo digital transformation.  More businesses are adopting process control and business ERP connected systems, IIoT devices, and advanced process control software to streamline operations. This transformation offers numerous benefits, including improved efficiency, real-time data analysis, and enhanced communication across various departments. However, it can also create vulnerabilities. Cybercriminals are increasingly targeting process manufacturing companies, often exploiting weak spots in various systems to gain unauthorized access.

The consequences of a cyber-attack can be severe. Process manufacturers often deal with sensitive information, including proprietary formulas, customer data, and operational metrics. A breach not only risks this information but can also lead to regulatory and compliance issues, legal repercussions, and loss of customer trust. In markets where reliability and safety are paramount, such as food, pet food, chemicals, power generation, as just a few examples, the implications of a cybersecurity incident can be devastating, not unlike a food or pet food safety and recall issue. This makes understanding industrial cybersecurity not just important, but essential for survival in today’s manufacturing environment.

Process control systems, which manage and monitor manufacturing processes in the previously mentioned industries, can be particularly vulnerable to cyber threats. These systems include HMI/PLC and PC-based control systems, Supervisory Control and Data Acquisition (SCADA) systems, and Distributed Control Systems (DCS’s). These systems are integral to production operations in all these industrial and agricultural market segments. They are often interconnected with business systems, extending the vulnerability both ways. When Cybercriminals target these systems, they can disrupt production processes, compromise product quality and administrative systems, and even pose safety risks.

One common attack method involves exploiting software vulnerabilities. Systems developed before cybersecurity became a major concern are particularly susceptible to attacks that can manipulate their operations. For example, a hacker could access a control system and alter its settings, causing machinery to operate outside safe parameters, which may lead to hazardous situations.

Moreover, attackers can also use techniques like phishing to gain access to credentials that allow them to enter control systems. Once inside, they may deploy malware that not only disrupts operations but can also steal sensitive data, further complicating recovery efforts. The increasing connectivity of process control systems to broader IT networks creates more entry points for cyber threats, emphasizing the need for robust industrial cybersecurity measures.

In process manufacturing, several types of cyber threats are possible that can impact operations. Recognizing them is important for effective prevention and correct response:

1. Ransomware: One of the most prominent cyber threats in recent years has been ransomware attacks. These involve encrypting a company’s data and demanding payment for its release. Can you imagine your proprietary formulas and ingredient information held ransom? These attacks can bring operations to a standstill, costing not just in ransom but also in downtime, lost productivity, and lost customers, market share, etc. For instance, a food processing facility might have production halted entirely, risking not just financial losses but also potential harm to consumer health if unsafe products are released due to compromised systems. This could be catastrophic and a business ELE (extinction level event).
2. Phishing: Cybercriminals often use deceptive emails or messages to trick employees into providing sensitive information or downloading malicious software. A single click could compromise an entire system, leading to data breaches and system outages. These attacks can be highly sophisticated or “deep fakes”.  This makes it essential for employees to be well-trained in recognizing suspicious communications.
3. Malware: Malware encompasses various types of malicious software designed to disrupt, damage, or gain unauthorized access to systems. In a manufacturing setting, it can sabotage operations, compromise production quality, and steal sensitive data. This is especially alarming in process automation, where malware could manipulate equipment, resulting in dangerous situations or the production of faulty or harmful products. Such incidents may lead to costly product recalls, significant financial losses, and a decline in customer trust.
4. Insider Threats: Not all threats come from outside the organization. Sometimes, employees can pose a risk, either on purpose or by mistake. These insiders often have access to important systems and information, so it’s crucial for companies to keep an eye on who has access and how they’re using it.
5. Denial of Service (DoS): These attacks are malicious attempts to disrupt normal functioning of the targeted computer system, server, or network by overwhelming it with a flood of traffic and requests. This overwhelms the targeted system and causes them to crash. For process manufacturing operations, this can mean significant downtime and loss of productivity, with aftershocks that can impact supply chains, customer satisfaction, and brand loyalty.

Understanding these threats is the first step in reducing and alleviating the risk associated. By knowing what to watch for, companies can implement measures to protect their systems and data.

The impact of a cybersecurity breach in process manufacturing can be serious and wide-ranging. Companies suffering a cybersecurity attack often face immediate financial losses, along with potential regulatory fines, legal fees, and the expenses of fixing compromised systems. Moreover, damage to a company’s reputation can have lasting effects on customer trust and loyalty, and diminished market share.

For instance, think about a food processing company hit by a ransomware attack. If production stops, it not only loses money during the downtime but also risks missing delivery deadlines, which can hurt relationships with suppliers and products going off the shelves of stores, and customers seeking other brands. If sensitive customer data is exposed, the company might face lawsuits and significant reputational damage.

In industries like baking, food production, and pet food/treat manufacturing, where safety and regulatory compliance are crucial, the risks are even greater. A cybersecurity breach could allow unsafe products to reach consumers, leading to recalls and serious health hazards. This underscores the urgent need for strong cybersecurity measures to protect both business interests and consumer safety.

The financial costs can be overwhelming. Industry reports suggest that the average cost of a data breach can reach millions of dollars, considering not just immediate repair costs but also long-term damage like lost customers and market share. Companies need to recognize that investing in cybersecurity isn’t just an expense; today it is essential for maintaining operational integrity and building customer trust.

How can process manufacturing companies improve their cybersecurity posture? Here are some steps you can take, beginning right now:

1. Perform a Risk Assessment: Begin by evaluating your current systems and processes. Identify potential vulnerabilities. Assess the likelihood and impact of different types of cyber threats. This will help prioritize your cybersecurity tasks and investments. Consider engaging with cybersecurity experts to perform a thorough assessment. They can identify weaknesses you might overlook.
2. Implement Strong Access Controls: Limit access to sensitive data and systems to only those employees who absolutely need it. Make sure that your process control software applications include multiple security level access controls, and ensure they are setup and used. Use MFA (multi-factor authentication) to add an extra layer of security. This step can drastically reduce the risk of unauthorized access to your systems and is a critical component of a strong security strategy.
3. Regularly Update Software/Hardware: Keep all process control software and hardware systems, including operating systems and applications, up to date. It is not unusual to find process manufacturers operating with computer OS (operating systems) that are outdated and no longer supported by the OS or process control software manufacturer.  Don’t wait to upgrade your process control system OS and process operating software until you have a major problem and are shut down. Cybercriminals often exploit known vulnerabilities in outdated software. Establish a regular schedule for updates and ensure that all staff are trained in the importance of maintaining current software.
4. Train Employees: Your workforce is often the first line of defense against cyber threats. Provide regular training on cybersecurity proven techniques and procedures, including how to recognize phishing attempts and handle sensitive information securely. Create a culture of security awareness within your organization, where employees feel empowered to report suspicious activities without fear of reprimand. Help your employees understand the need for security and to migrate the culture change that may be needed.

5. Develop an Incident Response Plan: Prepare for a breach. In the event of a cybersecurity breach, having a well-defined response plan can help minimize the damage to your systems and your business, short and long term. Ensure that all employees know their roles and responsibilities during an incident. Regularly test and update your incident response plan to adapt to new threats and ensure everyone is ready.
6. Backup Data Regularly: Regular backups are essential for quickly restoring operations after a cyber incident. Make sure to store your backups in a secure location and test them periodically to confirm that they work. A helpful guideline to follow is the 3-2-1 rule: keep three copies of your data on two different types of media, with one copy stored off-site.
7. Monitor Systems Continuously: Make sure that you have tools to monitor your systems for suspicious activity. Early detection helps avoid or reduce the impact of a possible cyber-attack breach. Consider using intrusion detection systems that can alert your IT team to unusual behavior in real time.

To sum up, here are the key points to keep in mind  regarding cybersecurity in process manufacturing:

• Industrial cybersecurity is crucial for protecting sensitive data and ensuring smooth operations.
• Be aware of the various types of cyber threats that could affect your organization.
• The impact of a breach can be serious, leading to financial losses, damage to your reputation, and compliance issues.
• Create a comprehensive cybersecurity strategy that includes risk assessments, controls to system and equipment access, employee training, and plans for responding to incidents.
• Keep your process control software and hardware systems up-to-date. This is essential for business success. OS’s and hardware systems go out-of-date after several years, unsupported over time. Stay on top of this and consult your process control system supply partner for best advice and timing of any updates.

By focusing on these areas, manufacturers can greatly reduce their risk of cyber threats and strengthen their overall security.

As process manufacturing increasingly adopts digital technologies, the importance of cybersecurity is more critical than ever. By understanding the risks and taking proactive steps, companies can protect their assets, ensure compliance, and maintain their reputation. In an environment where cyber threats are constantly changing, staying alert is essential. The goal should be to not just respond to incidents, but also to cultivate a culture of security to protect against them, and that reaches every level of the organization.

Industrial cybersecurity isn’t just the job of the IT department; it’s a commitment that involves everyone. Raise awareness, prioritize security. This will allow manufacturers to create a safer environment, ensuring the reliability of operations for many years to come. Investing in cybersecurity is investing in the future—one that will yield benefits in safety, trust, and business continuity.

With over 50 years of expertise in custom engineering solutions for process control and automation, material weighing, ingredient batching, liquid handling, and much more, Sterling Systems & Controls proudly has the experience to provide you with expert guidance to achieve your automation and process improvement goals with cybersecurity. Contact us today to discuss how our knowledge and expertise can align with your goals, and how you can continue your journey toward manufacturing excellence!