August 28, 2025 Building Cyber Resilience on the Factory Floor

Cyber resilience starts with people. Empower your factory floor with training to fight phishing, ransomware and evolving threats.

By John Trest

Manufacturing continues its digital transformation, and the sector continues evolving into a highly connected and automated ecosystem. Smart factories, IoT-enabled machinery, and cloud-based platforms are now standard components of modern production environments, fueling gains in efficiency, quality, and responsiveness. However, they also introduce cybersecurity vulnerabilities.

Cybersecurity in manufacturing is not, however, only a technical issue; it is fundamentally a human one. I’ll explain.

The Complex Threat Landscape That Manufacturing Has Become

You’re in manufacturing. You likely understand that the sector faces a unique blend of cybersecurity risks, shaped by the critical nature of your operations, legacy infrastructure, and sprawling supply chains. Many plants rely on a combo of IT and OT (operational technology) systems that are increasingly integrated to streamline processes.

Such approaches also expand the attack surface, making it easier for malicious actors to move laterally across networks once access is gained.

Ransomware remains a significant threat. No surprise there. Cybercriminals are acutely aware that even brief periods of downtime potentially result in millions of dollars in lost productivity and contractual penalties for manufacturers. Therefore, those in manufacturing have become a favored target.

Recent industry reports indicate that nearly half of cyberattacks in the manufacturing sector involve ransomware, which is often deployed through phishing emails or the exploitation of known software vulnerabilities.

Equally concerning is the increasing sophistication of attacks. For example, phishing emails can be created with generative AI platforms and tailored to mimic internal communications with alarming accuracy. Some attackers employ “callback phishing” techniques, where they initiate contact through seemingly harmless emails that eventually escalate into high-risk conversations or remote access requests.

These threats often bypass technical defenses (IT solutions) and rely instead on human fallibility, which is rife with exploitable opportunities.

The Human Element: Vulnerability or Asset?

Human error remains a leading cause of data breaches in manufacturing. Your employees click on malicious links and fail to follow access control protocols; well-intentioned employees can unwittingly expose your organization to substantial risk. According to widely cited industry research, nearly seven out of ten breaches in recent years can be traced back to human factors.

But this sobering statistic also reveals a powerful opportunity. If human error contributes to the majority of breaches, then human action—guided by awareness and training—can be a frontline defense. When manufacturers invest in building a security-aware workforce, they gain a powerful buffer against evolving threats.

Unfortunately, in many production environments, cybersecurity training is still often pushed aside due to other priorities, such as tight production schedules, ever-changing shift-based workforces, and a focus on output, all of which make it challenging to prioritize training. Security awareness training programs are often viewed as “let’s get this done” one-time compliance checklists instead of as an ongoing component of an organization’s culture.

Embedding Awareness in the Manufacturing Workflow

To be effective, cybersecurity training must be practical, relevant, and non-disruptive. Manufacturers are increasingly adopting microlearning approaches to meet these goals. These short, focused training modules, typically lasting no more than two or three minutes, can be easily completed during shift transitions or equipment downtime. Their brevity allows for frequent reinforcement, without interfering with production goals.

Another best practice is tailoring training to specific roles. The risks faced by a maintenance technician are different from those faced by a procurement manager or an R&D engineer. Training that aligns with job responsibilities helps employees recognize the threats most relevant to their daily work.

Your finance and procurement teams are typical targets of business email compromise (BEC) attacks. These involve fraudulent invoices or impersonated communications from executives or suppliers, and many sophisticated organizations across the globe have fallen for them.

Your engineering and technical teams also may become vulnerable to data integrity risks and unauthorized access to design systems, but role-based training can help these teams develop the judgment needed to respond appropriately.

Beyond training content, delivery, and engagement are key to security musts. Behavioral science has shown that without reinforcement, people forget most of what they learn within days. Known as the “forgetting curve,” this phenomenon is countered through gamification, periodic quizzes, and simulated phishing campaigns.

By rewarding proactive behavior and creating friendly competition among departments, organizations can foster a culture where secure behavior becomes second nature.

Staying Current in a Rapidly Evolving Landscape

The threat landscape is not static. New technologies and attack methods are emerging constantly, and manufacturers must adapt accordingly. Awareness programs must incorporate lessons from real-world breaches that highlight emerging tactics.

For example, attackers have begun leveraging deepfake technologies—audio or video impersonations that mimic the voices of executives—to request urgent wire transfers or access to sensitive data. Similarly, compromised vendor accounts or cloud-based tools may be used to send seemingly legitimate requests that bypass internal scrutiny. These tactics are particularly effective when employees lack current training on evolving threats.

Supply chain vulnerabilities also remain a serious concern. High-profile breaches stemming from third-party software vulnerabilities have affected a wide range of sectors, including manufacturing. As organizations become more interconnected, employees must learn to verify requests, question unusual behavior—even from familiar sources—and escalate concerns appropriately.

Aligning Cybersecurity with Business Goals

A cybersecurity awareness program supports manufacturing objectives by helping to preserve uptime, maintain product quality, and ensure timely delivery. A single cyber incident can not only cause production delays but also undermine hard-earned customer trust and damage brand reputation.

Cybersecurity training also plays a crucial role in ensuring regulatory compliance. Standards such as the Cybersecurity Maturity Model Certification (CMMC) and ISO 27001, as well as sector-specific regulations, emphasize the importance of employee awareness as a key pillar of risk management. As global data privacy laws become more stringent, with the introduction of the EU AI Act and the expansion of U.S. state-level legislation, demonstrating due diligence through training will become even more critical.

The Role of Leadership

No awareness initiative can succeed without the support and buy-in of leadership. When cybersecurity is positioned as a strategic priority by executive teams—not just an IT issue—it becomes embedded in company culture. Leaders who actively support awareness programs, participate in training, and communicate openly about risks and expectations set a powerful example.

Communication also matters. Regular updates, incident reviews, and recognition of good security practices can reinforce the message that cybersecurity is everyone’s responsibility. When employees see that their actions have a direct impact on organizational resilience, they are more likely to remain engaged.

Looking Ahead: Resilience Through Empowerment

As the digital transformation of manufacturing continues, cyber threats will become increasingly sophisticated. But manufacturers are not powerless. By investing in targeted, engaging, and regularly updated awareness programs, organizations can equip their workforce to serve as the first line of defense against cyber threats.

Cyber resilience on the factory floor does not stem solely from technology, but from informed, empowered employees who understand the stakes and are prepared to take action. In your business, operational disruptions have wide-reaching implications, from lost revenue to compromised safety and interrupted supply chains. The value of awareness cannot be overstated.

The future of manufacturing is bright, connected, and data-driven. To be truly sustainable, it must also be secure.

About the Author:
John Trest is chief learning officer, VIPRE Security Group

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