From artificial intelligence to robotics and machine vision, manufacturers realise they must invest in these technologies to stay competitive.

This commitment is giving rise to smart factories, with new levels of connection for greatly increased productivity and flexibility.

However, the integration of smart technologies also increases vulnerability to industrial cybersecurity threats.

Indeed, ransomware attacks in the manufacturing sector increased by 38% from 2025 to 2026, with average downtime costs exceeding $2.3 million per incident.

There’s a clear need for the prioritisation of digital security at every stage, from the development to the integration, and continued use of such systems.

The Rising Cybersecurity Risk 

Rockwell Automation’s State of Smart Manufacturing Report reflects the scale of the industrial cybersecurity threat, ranking it second on the list of external risks to growth.

Nearly half of manufacturers have experienced at least one cybersecurity incident over the past year, with the majority realising the need for significant investment in the strengthening of  Information and Operational Technology (IT and OT) security.

Going beyond the prevention of cyber attacks, the aim should be to maintain secure, reliable, and efficient production in the connected smart factory.

There’s a clear need for the integration of secure systems, with the use of AI to detect and defend against a range of digital dangers.

Smart Factories In Danger

With the connection of everything from IoT systems to robotics and AI analytics, the attack surface is dramatically widened.

Outdated systems, disconnected networks, and the lack of industrial cybersecurity knowledge only add to the risks.

A single security breach can have a domino-like effect, potentially leading to unplanned downtime, compromised product quality, safety risks, and supply chain disruptions.

There’s also the prospect of heavy reputational damage and regulatory penalties.

From Prevention to Resilience

Resilience should be the aim, with manufacturers taking steps for secure, reliable, and efficient production in the connected environment.

This will involve a combined strategy, with the adoption of a secure-by-design approach and the use of AI systems to monitor and detect emerging threats.

The first step should be to create an inventory of technological assets, identifying the dependencies and where breaches could have the greatest impact.

There must also be a distinct separation between IT and OT zones.

People, processes, and technology should come together for the greatest protection against malicious cyber attacks.

Clear and actionable guidelines will be vital for effective containment, safe shutdown, and recovery.

Integrating AI for Threat Detection

As Rockwell Automation’s Stephen Ford has said, “AI is a critical part of the modern security stack, enabling manufacturers to detect threats in real time, maintain productivity, and stay ahead in an increasingly aggressive threat landscape.”

This is a shared belief, with 61% of cybersecurity and IT professionals reported as prioritising investment in AI and machine learning for security.

Such systems can be used to identify any machine performance deviations that might indicate ransomware or data theft.

As an example, Ishida’s Sentinel 5.0 can be easily integrated across the factory floor for continuous remote monitoring.

Other AI-powered systems are being integrated for the identification of vulnerabilities and automated safety.

Building a Cyber-resilient Culture

There’s shared recognition of the need to equip factory workers at all levels with knowledge of industrial cybersecurity practices and standards.

This calls for training specific to different roles, from the machine operator to the maintenance technician and engineer.

As an example, industrial-themed lures, such as fake maintenance alerts, may be used to test and identify the need for improved awareness.

Ransomware scenarios might also be set up to validate and improve the responses of operations and IT staff.

There should be clear instructions on how to respond following different types of cyber breaches.

Such instructions and training should be regularly updated, with refreshers to keep pace with evolving threats.

Governing Industrial Cybersecurity

From the factory management to the machine operatives, ownership for cybersecurity must be clearly defined at all levels.

Communication and collaboration will be vital, with production teams, engineers, and managers working together in the manufacturing company’s best interests.

This should make for a continuous and shared commitment to industrial cybersecurity, with the regular assessment of vulnerabilities and maintenance as needed.

Those companies making the cybersecurity investment will stand the best chance of staying ahead in the increasingly connected world.

Looking to a Secure Future

Not simply an option, cybersecurity is essential for ongoing compliance, customer satisfaction, and operational excellence.

As the leading trade association for automation suppliers and technology end users, Automate UK is committed to spreading the message and sharing best practices for cyber resilience.

From consultancy on the integration of secure systems to the arrangement of expert-led webinars on emerging threats, our members enjoy a wide range of benefits.

Join us in building a secure and resilient future for UK industry.