Securing the digital factory: Building a fortress for Industry 4.0

This blog has been written by Darren Hogan, Director of Portfolio, at Nasstar. 

We’re at a defining moment in technology. Industry 4.0 has made system integration essential, but having the right experts to build and maintain these solutions is equally important. However, because so many systems are interconnected, the risk of vulnerabilities and disruptions is ever-present. 

To ensure the security and efficiency of a digital factory, businesses need a single, trusted service partner to manage an increasingly complex web of technologies. This unified approach not only reduces risks but also streamlines maintenance, allowing companies to focus on innovation rather than troubleshooting.  

In this post, we’ll explore why a cohesive security strategy is essential for building a resilient digital ecosystem in Industry 4.0. 

The security challenge of Industry 4.0 

As manufacturers continue to strive towards Industry 4.0, factories will become "smarter", more connected, and increasingly reliant on data to drive efficiency and innovation. However, as the digital threads that weave through operational technology (OT) and information technology (IT) grow more intricate, opportunities for the threat actor evolve alongside them. 

Gaze into our crystal ball for a second...imagine a state-of-the-art factory with automated guided vehicles (AGVs), smart machinery, and AI-driven insights. Now consider a threat actor exploiting a single unsecured entry point, (malware installed on an unsuspecting third-party maintenance laptop as an example) and accessing sensitive data such as proprietary designs or other such crown jewels.  

What if the threat actor could disrupt production altogether? Terminally shutting down production lines by sending malformed or malicious control logic messages to industrial control systems can stop output and revenue. The consequences don't bear thinking about. 

In traditional factories, physical security measures such as perimeter fences and access controls keep intruders out, but digital factories need more than just "locked doors". They need a comprehensive digital defence strategy that spans every layer of the infrastructure. 

Secure by Design 

Security has to be built into the foundations of any modern digital infrastructure. Whether that’s ensuring public cloud infrastructure platforms are built leveraging cloud governance, risk, and compliance (GRC) frameworks and controls, or real time threat detection and response capabilities with IT/OT infrastructure. To do this, there are several core components that require focus when locking down the digital factory. 

Network segmentation and secure connectivity 

A secure factory architecture starts by isolating critical OT systems from IT networks. However, effective network segmentation isn’t enough without robust, secure connectivity linking cloud, edge, and factory floor.  

Software-Defined Connectivity (SDC), coupled with Secure Service Edge (SSE) technology, uses encryption and zero-trust principles to provide control over application and data access. 

Operational Technology (OT) security 

Unlike traditional IT systems, OT devices often run legacy protocols that weren’t built with modern cyber security in mind. OT security solutions combine asset discovery, real-time monitoring, and anomaly detection to identify threats before they impact production.  

Certain solutions can also deliver fine grained deep packet inspection capabilities between systems for industrial protocols such as Modbus, DNP3, and IEC 60870-5-104, down to control logic message level. 

Third-party access 

Manufacturers often rely on third-party vendors for maintenance and updates to machinery. However, third party access to physical ICS/OT systems can introduce security risks. Only through a combination of remote, policy-based access for remote support engineers, and strict vetting of foreign media entering the factory floor (and exiting again to enforce data loss prevention) for on-site remediation activities, can organisations address these potential gaps in security posture.  

Governance, risk, and compliance (GRC) 

With GRC frameworks, manufacturers can enforce robust data governance policies that manage and secure data access across both on-premise systems like data historians and hyperscaler data repositories used for machine learning. Examples of public cloud GRC frameworks include AWS Well-Architected Framework, Azure Policy, and Google Cloud Compliance, which support governance and compliance requirements for secure data access. 

How to ensure security with Industry 4.0 

Knowing you need to secure your digital factory is one thing, but it’s vital that you understand how to do this in the era of Industry 4.0. There are several points to consider when securing your digital factory.  

The OEMs (Original Equipment Manufacturers) that provide systems and hardware aren’t immune to vulnerabilities. Many of them were designed for an age where the best defence against external attack was an air gap between the system and an external network. However now, to get data from the system to pursue a digital transformation strategy, you may need to connect it to the internet.  

Remember that the internet is full of people who are trying to get access to your systems and data to either shut you down, extort money out of you, or likely both. Your doorway to the internet might allow you to send data out, but it also lets data and risk in. In response, you should ensure your perimeter security controls are robust, consuming threat intelligence from reputable sources, and employing unified threat protection features such as IDS and IPS. 

Applying software updates to critical industrial control systems and manufacturing equipment can invariably mean taking down a plant line, impacting productivity. This can cost the company time and money. Furthermore, the equipment maintainer may need to send an engineer to the facility to apply the software update locally. The engineer may come with their own laptop, the governance and control of which falls outside of the manufacturer, which could harbor malware or malicious code that can be transferred to the plant equipment causing further disruption.  

As a solution, manufacturers can make use of pre-staged endpoint devices that are appropriately protected with Endpoint Detection & Response (EDR) software, incorporating removable media scanning such as USB drives to ensure any third-party engineer can perform the upgrades using an approved device. For OEM’s using remote access VPN’s, these should be reviewed and replaced with ‘conditional access’-based technologies to restrict access to specific systems based on role. 

These are just a small number of potential problem statements that can be associated with a digital transformation journey. Closing these security gaps across the entire secure digital factory ecosystem needs close attention from a trusted partner.   

A unified approach with Nasstar 

Just as a house extension requires architects, electricians, and plumbers working in harmony, a secure digital factory requires seamless collaboration across connectivity, cloud platforms, data, OT, and application layers. Nasstar’s unique ability to integrate these elements into a unified, secure ecosystem ensures manufacturers aren’t juggling multiple vendors or piecemeal solutions. 

By partnering with Nasstar, manufacturers gain more than just technology; they gain a strategic partner who understands their business, speaks their language, and fortifies their operations against an ever-evolving threat landscape. 

Securing the digital factory is an investment in long-term innovation and growth. Let Nasstar help you build a secure foundation that not only defends against threats but also accelerates your transformation journey. 

Connect with us today and let us secure your path to Industry 4.0.