As smart factories become the cornerstone of modern manufacturing, integrating Industrial IoT (IIoT), AI-driven automation, and cloud platforms, cybersecurity has emerged as a non-negotiable priority. The convergence of operational technology (OT) and information technology (IT) creates unprecedented vulnerabilities, with cyberattacks on manufacturing now outpacing those on financial sectors. For IT managers, balancing innovation with security requires a structured approach, one that aligns cutting-edge frameworks like IEC 62443 with scalable network solutions such as co-managed SD-WAN. This article outlines seven critical steps to fortify smart factories against evolving threats while leveraging SD-WAN’s capabilities to enhance resilience and operational simplicity.
1. Conduct a Comprehensive Risk Assessment
Begin by benchmarking your current security posture against internationally recognised standards like IEC 62443 and NIST SP 1800-10. Smart factories must evaluate risks across all layers, from legacy PLCs to cloud-based analytics platforms. For example, unpatched OT devices running outdated firmware remain prime targets for ransomware gangs seeking to disrupt production lines.
SD-WAN integration: A co-managed SD-WAN service, such as Digital Carbon’s offering, provides centralised visibility into network traffic across distributed sites. This enables IT teams to identify vulnerabilities in real time, such as unauthorised access attempts or unencrypted data flows between edge devices and cloud platforms.
2. Implement Network Segmentation Using Zones and Conduits
The IEC 62443 standard advocates dividing networks into zones (grouped assets with shared security requirements) and conduits (secure communication pathways). For instance, segmenting robotic assembly lines from enterprise IT systems limits lateral movement during breaches.
SD-WAN advantage: Modern SD-WAN solutions enable segmentation through software-defined policies, isolating critical OT systems without physical reconfiguration. Digital Carbon’s service, built on VeloCloud platform, allows IT managers to define granular access controls for IIoT devices, ensuring that sensors in a production zone cannot communicate directly with administrative networks.
3. Adopt Zero-Trust Principles Across OT/IT Environments
Zero-trust architectures, where no user or device is inherently trusted, are no longer confined to corporate IT. In smart factories, this means authenticating every access request, whether from a human operator or an AI-driven quality-control system.
SD-WAN synergy: Zero Trust SD-WAN solutions, such as those integrating Zscaler’s Security Service Edge (SSE), eliminate implicit trust in branch connections. By redirecting traffic directly to cloud security platforms, rather than backhauling through data centres, factories reduce latency while enforcing strict identity-based policies. Digital Carbon’s co-managed model simplifies this transition, offering preconfigured Zero Trust frameworks tailored to industrial use cases.
4. Secure Remote Access with Co-Managed SD-WAN
Remote monitoring and third-party vendor access are inevitable in smart factories but introduce significant risks. Traditional VPNs often lack the granularity to secure OT environments, making them vulnerable to credential-stuffing attacks.
SD-WAN resolution: A co-managed SD-WAN service replaces vulnerable VPNs with encrypted, application-aware tunnels. Digital Carbon’s solution, for example, combines application prioritisation with enterprise-grade firewall services, ensuring that only authorised personnel can access PLCs or SCADA systems. Additionally, their centralised orchestrator allows IT teams to revoke access instantaneously during incidents, a critical feature for factories with rotating contractor teams.
5. Establish Continuous Vulnerability Management
Legacy OT systems, such as decades-old CNC machines, often cannot be patched without halting production. However, neglecting updates in IT/OT convergence zones creates exploitable gaps.
SD-WAN enablement: Co-managed SD-WAN providers like Digital Carbon automate patch management across distributed sites. Their platform’s centralised dashboard identifies unpatched SD-WAN routers or edge devices, while integrated intrusion prevention systems (IPS) block exploits targeting known vulnerabilities. For factories reliant on legacy equipment, this layered defence buys time for scheduled maintenance windows.
6. Develop an Incident Response Plan Tailored to OT Realities
When a German automotive supplier suffered a ransomware attack in 2023, its inability to isolate compromised robotic welders led to a 72-hour production halt. Smart factories need incident response plans that prioritise OT availability without compromising forensic integrity.
SD-WAN contribution: Digital Carbon’s SD-WAN incorporates real-time analytics and flow logging, enabling IT teams to trace attacks across network segments. During a breach, managers can swiftly reroute traffic via backup links, such as 5G or LTE, to maintain production while isolating affected zones.
7. Foster a Culture of Cyber Resilience Through Training and Collaboration
Human error remains the leading cause of industrial breaches, from misconfigured firewalls to phishing scams targeting plant managers. Regular training programmes, coupled with cross-departmental drills, are essential.
SD-WAN’s role: Co-managed services alleviate the burden on in-house teams, allowing IT managers to focus on strategic initiatives. Digital Carbon’s model includes collaborative workshops to upskill IT staff on SD-WAN policy creation, threat hunting, and compliance reporting.
Conclusion: Building a Future-Proof Security Posture with Co-Managed SD-WAN
Securing smart factories demands more than checklist compliance, it requires a dynamic, holistic strategy that unites cybersecurity frameworks with agile networking solutions. By adopting a co-managed SD-WAN approach, manufacturers gain access to enterprise-grade security features zero-trust policies, automated patching, and granular segmentation, without the overhead of maintaining complex infrastructure.
Digital Carbon’s expertise in blending VeloCloud’s SD-WAN with bespoke security services exemplifies this synergy. The solution not only addresses immediate threats but also scales alongside emerging technologies like 5G and edge computing. For IT managers navigating the complexities of Industry 4.0, partnering with a co-managed provider transforms cybersecurity from a cost centre into a catalyst for innovation.
Digital Carbon specialises in co-managed SD-WAN services, combining VeloCloud’s cutting-edge technology with tailored security frameworks for smart factories. Explore how our solution simplifies compliance, reduces downtime, and future-proofs your industrial networks at digitalcarbon.io.
