The Cybersecurity Playbook for Automation and Control Systems

Why Industrial Automation Needs Protection

Industrial automation runs factories, power grids, water systems, and transport. If these systems fail or get hacked, real-world damage happens. Production stops. Power goes out. Safety risks increase.

Cyberattacks on industrial systems are rising. The 2023 IBM X-Force Threat Intelligence Index reported a 28% increase in attacks on operational technology (OT) compared to the previous year. These systems often run 24/7 and can’t afford downtime, making them tempting targets.

In many cases, the technology is old. Some plants still run controllers from the 1990s. They weren’t built for a connected world. That’s why modern security is now a must-have.

Common Weak Points

Outdated Equipment

Many industrial controllers can’t run modern security software. They may lack encryption, firewalls, or update capabilities.

Network Gaps

OT and IT networks often mix without proper segmentation. Hackers can get in through a laptop on the office network and move into the control system.

Poor Access Control

Shared passwords and unsecured remote access are still common. In some plants, anyone with physical access can plug into control panels.

Lack of Monitoring

Unlike IT systems, industrial networks often have minimal threat detection. Attacks can go unnoticed for weeks.

What Happens When Things Go Wrong

In 2021, a U.S. water treatment facility was hacked. The attacker tried to change chemical levels in the water. In 2017, the Triton malware targeted safety systems at a petrochemical plant, potentially putting workers at risk.

Frederic Lauzier recalls a factory he worked with that unknowingly left an old engineering workstation connected to the internet. “It had default passwords and no firewall,” he said. “We found it during an audit. If someone with bad intentions had found it first, they could have taken control of key production equipment.”

Steps to Make Systems Safer

Segment the Network

Separate OT from IT. Use firewalls and managed switches. Limit communication to only what is necessary.

Control Access

Use unique credentials for each user. Require strong passwords and regular changes. Implement role-based permissions so people only have access to what they need.

Update and Patch

When possible, keep controllers, firmware, and software up to date. If hardware can’t be updated, use compensating controls like isolated networks or external security devices.

Monitor for Threats

Install intrusion detection systems (IDS) that work with industrial protocols. Review logs regularly. Watch for unusual patterns, like commands at odd hours.

Train Staff

Security is everyone’s job. Teach operators and engineers to recognise phishing attempts, suspicious devices, and unsafe behaviour.

Building Security into Design

When installing new equipment, make security part of the specification. Require vendors to support encryption, authentication, and secure remote access.

Ask how patches are delivered. Request a security lifecycle plan for the equipment. This avoids surprises years down the road.

Balancing Security and Uptime

One challenge is that industrial systems often can’t stop for updates. Security changes must be planned carefully. Some companies schedule rolling updates during maintenance windows to avoid downtime.

Lauzier explains, “We once had to patch a critical system at a hydro plant. Shutting it down wasn’t an option during peak demand. We staged the update on a twin system first, tested it for a week, then switched over without interrupting operations.”

Statistics to Keep in Mind

• 75% of OT organisations experienced at least one intrusion in 2022 (Fortinet OT Security Trends Report).
• 47% of breaches in OT environments start through IT systems.
• Average recovery from an OT cyber incident costs over $3 million and takes more than 20 days to fully restore operations.

Recommendations for Action

1. Map Your Assets – Know every connected device, even old ones in storage.
2. Set Up Alerts – Use monitoring tools to flag unusual behaviour.
3. Enforce Access Rules – No shared logins, no unnecessary admin rights.
4. Backup Critical Data – Keep backups offline to avoid ransomware.
5. Plan for the Worst – Have an incident response plan ready and practice it.

The Future of Industrial Cybersecurity

More factories are moving toward predictive security—using AI to detect problems before they happen. Secure-by-design equipment is becoming a standard requirement for tenders. Governments are introducing stricter rules for critical infrastructure operators.

But the basics still matter most: keep systems separate, limit who can touch them, watch for trouble, and prepare to act fast.

As Lauzier puts it, “You can have the smartest AI in the world, but if your control cabinet door is unlocked, that’s where an attack will start.”

Protecting industrial automation is no longer optional. The risks are real, but the solutions are clear. Every plant, utility, and transport system can take steps today to make tomorrow safer.

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