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Cybersecurity · Manufacturing

Keep the line running when ransomware comes knocking

Why attackers favor manufacturers, how to separate shop-floor systems from office IT, and how to answer the security questions your customers now send.

Manufacturing tops attack statistics

Separate OT from office IT

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The short answer

Small manufacturers are attractive to attackers because downtime is expensive, older shop-floor systems are hard to patch, and customers depend on on-time delivery, so pressure to pay a ransom is high. IBM’s X-Force Threat Intelligence Index 2026 found manufacturing was the most attacked industry for the fifth year in a row, at 27.7 percent of the incidents IBM responded to in 2025.

The core defenses for a 25 to 100 person plant are: multi-factor authentication on email and remote access, backups that cannot be encrypted and are tested, a network that separates operational technology (OT) from office IT, controlled vendor remote access, and a written plan for running or restarting production during an incident. If you sell to defense or large OEM customers, expect formal security requirements in your contracts.

Why attackers go after manufacturers

  • Downtime costs. Every hour the line is down has a visible cost, which attackers use to push for payment.
  • Flat networks. In many plants, office PCs, machine HMIs, cameras and the ERP server share one network, so one infected laptop can reach everything.
  • Old systems. Machine controllers and PCs running vendor software often run unsupported Windows versions because the machine vendor never certified an upgrade.
  • Vendor remote access. Machine builders and integrators often have always-on remote connections that nobody reviews.
  • Valuable data. Drawings, programs, pricing and customer specifications are worth stealing for extortion.
  • Supply chain position. A small supplier can be a path into a larger customer.

In the manufacturing incidents IBM’s 2026 report covered, exploiting public-facing applications was the most common way in (32 percent), followed by valid accounts (16 percent). In plain terms: unpatched internet-facing systems and stolen logins.

Separate OT from office IT

OT means the systems that run physical processes: PLCs, HMIs, CNC controllers, SCADA, building systems and the PCs that program them. NIST Special Publication 800-82 Revision 3 is the U.S. government’s main guide to OT security. Its central idea for a small plant is segmentation: keep OT on its own network zone and tightly control what crosses into it.

  1. Map what you have. List every machine, controller and PC on the floor, what it talks to, and who supports it.
  2. Create separate zones. At minimum: office IT, OT, guest and vendor access. Use VLANs and a firewall between them, not just separate switches.
  3. Allow only what is needed. If the ERP needs production counts from one server, allow that one flow and block the rest.
  4. Block internet access from OT unless a specific machine truly needs it, and then only to named destinations.
  5. Protect machines you cannot patch with segmentation, application allow-listing and removing USB access where practical.
  6. Control vendor access. Replace always-on vendor connections with access that is approved per session, uses multi-factor authentication and is logged.

Backups and recovery that work for a plant

Recovery in manufacturing means more than restoring files. It means getting machines back to producing parts.

  • Back up the ERP, file shares, CAD and CAM data, and Microsoft 365 or Google Workspace
  • Keep copies of PLC programs, HMI projects, CNC programs and machine configurations, with version dates
  • Keep at least one backup copy offline or immutable so ransomware cannot reach it
  • Test restores, including rebuilding a machine-programming PC from scratch
  • Write down how to run production manually or from paper if the ERP is down, and for how long that is realistic

Our guide to backup and disaster recovery for small businesses covers recovery targets and testing in more depth.

Want to know how exposed your plant and office systems are? Our free Technology Health Assessment takes about 30 minutes of data collection. The next day you get a plain-language report rating your IT operations, cybersecurity, business continuity and more as controlled, needs attention, significant exposure or unknown, with a short list of next steps in order. It is yours to keep, with no obligation. Book your assessment.

What your customers will ask

Large customers increasingly send supplier security questionnaires, and some build requirements into purchase agreements. Expect questions about MFA, backups, endpoint protection, patching, incident response and who can access their drawings.

Defense suppliers face formal rules. The Department of Defense’s CMMC program began phase 1 on November 10, 2025, when contracting officers could begin adding CMMC requirements to new solicitations, starting with self-assessments. The CMMC program rule (32 CFR 170.3) schedules phase 2, which adds Level 2 third-party (C3PAO) certification assessments for many contracts involving controlled unclassified information, to begin November 10, 2026, followed by phase 3 in November 2027 and full implementation in November 2028. However, on July 13, 2026 the Department of Defense (also styled the Department of War) paused the phase 2 transition pending a program review, and as of early October 2026 no outcome had been announced, so the third-party assessment milestone is on hold. The program has not been cancelled: phase 1 self-assessments and SPRS affirmations, DFARS clause 252.204-7012 and the NIST SP 800-171 controls it requires remain in effect. Check the DoD CIO CMMC site for current status. If you handle defense work, confirm your required level with your prime contractor and qualified advisors now, because preparing for an assessment takes months.

A priority list for a 25 to 100 person manufacturer

  1. Multi-factor authentication on email, remote access, the ERP and any cloud portals.
  2. Endpoint protection on every office PC and every floor PC that can support it.
  3. Email filtering and a rule that any change to supplier or customer bank details is confirmed by phone.
  4. Separate OT and office networks with a firewall between them.
  5. Replace always-on vendor remote access with approved, logged sessions.
  6. Immutable or offline backups of business and machine data, with tested restores.
  7. Same-day removal of departed employees and contractors.
  8. A written incident plan that includes how production continues, plus your insurer’s breach line.
  9. A yearly review of unsupported systems with a plan to isolate or replace them.

NIST’s Manufacturing Extension Partnership (MEP) centers offer cybersecurity resources aimed at small manufacturers, and CISA’s StopRansomware site lists free guidance and services.

Practice the bad day before it happens

A one-hour tabletop exercise each year shows where your plan breaks. Gather the owner, plant manager, office manager and IT provider, and walk through a scenario: it is 6 a.m. Monday, office screens show a ransom note and the ERP will not load.

  • Who decides whether to shut down network connections to the plant floor?
  • Can the line keep running if office systems are down, and for how long?
  • Where are the printed contact numbers for your IT provider, insurer, key customers and machine vendors?
  • Who tells customers about delayed shipments, and what do they say?
  • How do you pay staff and suppliers if accounting is offline?

Write down the gaps you find, assign owners and fix the biggest ones first.

How JLB USA helps

JLB USA’s cybersecurity services include multi-factor authentication, access reviews, same-day removal of leavers, endpoint protection, updates, encryption, email security, monitored backups with tested restores, a written recovery plan and help with cyber-insurance and customer questionnaires. Our managed IT covers office IT and vendor management for businesses with roughly 25 to 100 employees, with on-site support in Atlanta, Birmingham and Chattanooga and remote support everywhere else. For defense contracts, confirm requirements with your prime and a qualified assessor.

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Questions we hear

Why are manufacturers targeted by ransomware?

Downtime is costly, networks are often flat, shop-floor systems are hard to patch and customers depend on deliveries. IBM’s X-Force Threat Intelligence Index 2026 ranked manufacturing the most attacked industry for the fifth year in a row.

What is OT/IT separation?

Keeping operational technology such as PLCs, HMIs and CNC controllers on its own network zone, with a firewall that allows only the specific connections needed between the plant floor and office systems.

Do small manufacturers need CMMC?

Only if they hold or seek Department of Defense contracts that include CMMC requirements. Phase 1 began November 10, 2025. Phase 2, which adds third-party Level 2 assessments, was scheduled for November 10, 2026 but was paused on July 13, 2026 pending review; self-assessments, SPRS affirmations and DFARS 252.204-7012 / NIST SP 800-171 obligations remain in effect. Confirm your required level with your prime contractor and qualified advisors.

How do we secure old machines that cannot be updated?

Isolate them on a separate network segment, block their internet access, limit USB use, use application allow-listing where possible, and plan replacement over time.

Should machine vendors have remote access to our equipment?

Only through access that is approved per session, protected with multi-factor authentication and logged. Always-on vendor connections are a common way attackers get in.

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