A production line failure is usually associated with a broken component, a worn-out part, or operator error. Increasingly, however, the source of the problem lies elsewhere, namely in cyberspace. With the rise of digitalization, factories are becoming targets for attacks that not only halt production but can also wreak havoc on controllers and threaten the security of the entire facility.
Maintenance departments are the first to encounter the consequences of such events. Unusual machine behavior, difficult-to-explain faults, or errors in process logic may signal that we're dealing not with a technical failure but with a cyberattack.
The factory in the digital age
Manufacturing is increasingly reminiscent of the halls of yesteryear, filled solely with mechanical equipment. Today's production lines are a network of sensors, controllers, operator panels, and SCADA systems that collect data and control processes in real time. Thanks to these systems, machines operate faster, more precisely, and with fewer errors.
However, digital transformation has opened doors that were previously unavailable in factories. Alongside classic faults, the possibility of external interference has emerged. All it takes is a loophole.
in the software, poorly secured remote access or lack of updates so that someone outside the plant could influence the operation of the machines.
Maintenance departments today stand at the intersection of two worlds: traditional mechanics and modern, networked automation. This new environment requires not only technical knowledge, but also an awareness that modern failures can result from actions that are not immediately apparent.
Why has industry become a target of cyberattacks?
Industrial systems control processes that determine the operation of entire plants. PLCs and SCADA systems are to factories today what the nervous system is to the body, and their paralysis causes the entire line to cease functioning. This presents an exceptionally attractive pressure point for cybercriminals, as the effects of an attack can be felt immediately and measurably.
An additional problem is the fact that many industrial facilities simultaneously use modern systems and devices installed more than a decade ago. These older components are not always easily updated, and their manufacturer may have discontinued support. This creates a patchwork of technologies in which finding the weakest link is not a major challenge for someone familiar with the specifics of automation.
History shows that attacks on industry are not abstract. Stuxnet demonstrated that malware can deliberately interfere with physical processes and alter machine operating parameters, and Pipedream highlighted the emergence of tools designed specifically to attack controllers and control systems. This indicates that factories have become targets of attacks not by accident, but with full awareness.
Cybersecurity in maintenance work
Today, daily maintenance tasks involve more than just servicing machines or scheduling inspections. With the digitalization of production, maintenance teams are also responsible for ensuring a plant's resilience to cyber threats. This requires a combination of technical, organizational, and control activities, which together create a barrier difficult for attackers to overcome.
The key is knowing what's running on the shop floor . An up-to-date inventory of devices and software versions allows you to quickly assess which components are vulnerable to attacks and where problems should be expected. It's similar to a spare parts warehouse; if you don't know what you have in stock, it's harder to plan an effective response.
Another pillar is the separation of office and industrial systems . The computer in the accounting office should not have a direct connection to the packaging line controller. Separating zones and controlling data flow ensures that even if something happens in the administrative network, it won't automatically transfer to the production floor.
Access control is equally important . Shared passwords, unauthorized accounts, or overly broad permissions can facilitate an attack. The principle of least privilege also applies to security: each employee has access only to the systems and resources necessary to perform their duties.
Daily maintenance tasks also include maintaining updates . Controllers and operator panels, like computers, require patches to close known vulnerabilities. Implementing these patches during a controlled maintenance cycle minimizes the risk of someone exploiting outdated software to introduce malicious code.
Monitoring for unusual machine behavior is crucial . Excessive network communication, sudden changes in operating parameters, or commands that don't align with process logic should be considered alarm signals. In such cases, a quick response from maintenance is crucial, as it allows the problem to be stopped before significant damage occurs.
Configuration and program backups are equally important . In the event of an attack, the ability to restore controller settings within hours, not days, can be the difference between downtime costing thousands or millions of zlotys.
Finally, it's worth mentioning exercises and simulations . Regularly reviewing how the maintenance team responds to emergencies under time pressure builds habits and facilitates action in critical moments. It's better to practice a scenario than to improvise in a crisis.
The role of humans in defending against cyberattacks
Even the most advanced security measures cannot replace human vigilance. Maintenance workers, thanks to their close proximity to machinery and familiarity with processes, are often the first to notice when something isn't working as expected. Such observations can be invaluable, as systems can't always distinguish between a simple anomaly and a genuine threat.
Everyday habits are equally important. Being careful when using data storage devices, not sharing passwords, and maintaining access rules are small actions that effectively close off some potential attack paths. It's the discipline in these seemingly simple actions that builds the first layer of protection.
The importance of training and collaboration cannot be overlooked. A maintenance team that understands attack scenarios and can report them quickly operates more effectively. Collaborative efforts with IT and security specialists create a cohesive line of defense. The maintenance department notices symptoms on the shop floor, while others analyze them online. Only such a combination ensures a complete and rapid response.
Cybersecurity in maintenance is now part of everyday responsibility. The world of automation has changed so much that, in addition to bearing replacement and controller servicing, there's a need to protect against attacks that strike at the very foundations of production.
Technology will continue to evolve, opening up new opportunities for industry each year, but it will also provide avenues for those who wish to use it against factories. This is why UR teams, acting consciously and in cooperation with other areas, are becoming one of the most important elements of defense.
People, not systems, determine whether a company can survive in cyberspace. And they determine whether digital transformation will mean growth or vulnerability.
