Industrial control system security: how to protect manufacturing from cyberattacks and reduce business losses

A production shutdown costs 2 million an hour - that is how much a business can lose for every 60 minutes of downtime caused by a cyberattack on automated control systems. We explain where security threats to industrial control systems come from, how to reduce risk with simple rules, and how to build protection to avoid multi-million losses.

Attackers constantly invent new ways to break into automated systems. These attacks target critical infrastructure (energy, transport, manufacturing) and can halt operations within minutes. But if you know how criminals operate, you can identify threats faster and reduce losses. Threats to industrial control systems and how they are carried out:

According to According to Kaspersky Lab, in early 2025 CIS was among the six regions worldwide where the number of attacks on industrial control system computers continued to grow, even though the global trend declined. Attackers are focusing on CIS industry - attacks are rising despite the global decrease.

Standard protection tools (basic firewalls, signature-based antivirus, and simple password policies) often cannot handle targeted attacks on industrial infrastructure. To avoid downtime and financial losses, you need a comprehensive security system.

It should combine technical, organizational, and software-based security measures. Technical measures- include installing equipment and configuring systems that physically prevent unauthorized access and attacks: - Firewalls between corporate and production networks. - Intrusion monitoring systems to detect abnormal activity. - Multi-factor authentication for access to critical systems. - Regular data backups with integrity verification. Organizational measures - are aimed at establishing operating rules and training staff, helping reduce risks caused by human factors. - Clear security policies for working with industrial control systems. - Staff training on identifying phishing attacks. - Regular security audits and penetration testing. - Incident response plans with assigned roles. Software measures - are related to software updating and configuration, protect against software vulnerabilities, and ensure secure data transfer between systems: - Timely updating of software and firmware for industrial control system components (applying patches to SCADA systems, updating PLC controller firmware and network routers). - Specialized industrial protocol protection systems (using security gateways for Modbus, OPC UA, PROFINET). - Cryptographic data protection (VPN tunnels for remote access, GOST data signing). - Centralized logging and analysis of security events (collecting logs from PLCs, HMIs, and servers in a SIEM system to detect anomalies).

Cyberattacks on industrial enterprises are becoming increasingly destructive. According to the study, in the first half of 2025, the number of attacks on CIS companies increased by 27%, reaching 63 thousand incidents.

At the same time 80%organizations suffered severe consequences, including production shutdowns and financial losses. We will look at real cases and how criminals carry out threats in industry and energy. The largest U.S. oil pipeline, Colonial Pipeline In 2021, it fell victim to a DarkSide ransomware attack. The attackers gained access to the pipeline control system through leaked employee credentials. The company shut down the pipeline for 5 days, triggering a fuel crisis.

We have prepared a list of recommendations to help managers apply the basic protections for automated systems. The checklist steps can be implemented quickly, even without a dedicated IT team, and will deliver results within the first month. 1. Start with a systems analysis, whose downtime will halt production. Assess the damage from attacks on each system and decide what to protect first. 2. Install firewalls. This will prevent attacks from spreading from the corporate network to the industrial one.

Set filtering rules for industrial protocols to block unauthorized commands. 3. Store critical data and verify its integrity.Make sure backups are stored separately from the main systems. Regularly test data recovery - this ensures they will work in an emergency. 4. Implement multi-factor authentication.The fewer permissions a user has, the lower the risk of error. Leaks most often happen through contractors.

5. Install security updates regularly.Without updates, vulnerabilities remain open for months. Test patches in isolation - this protects critical nodes without risking shutdown. 6. Run cyber hygiene and incident response drills. Use real examples from your industry - this increases employee engagement. Hold regular short sessions instead of occasional multi-hour lectures.

7. Check whether contractors comply with your security requirements.Include cybersecurity clauses in every contract. Regularly audit their access systems to your infrastructure. 8. Monitor abnormal activity in systems 24/7. Set up alerts for suspicious events in real time. Start by monitoring the most critical systems that production continuity depends on. 9. Define who is responsible for what in the event of an attack.

Specify the response sequence for different types of incidents and regularly run drills to practice the plan. 10. Regularly check the system for vulnerabilities. External audits help uncover vulnerabilities you cannot see from the inside - by fixing them, you reduce the risk of downtime and losses.