Protecting Industrial Networks: Zero Trust Principles for Modern Manufacturing

Manufacturing is one of the most targeted industries for cyberattacks. Ransomware alone carries an average recovery cost of $1.67 million, and even brief downtime can affect production, delay shipments, and impact revenue.

The challenge is that many manufacturing environments weren’t built for today’s cyber risks. Factory floor systems and industrial protocols were designed for uptime and reliability, not security, leaving critical operational systems exposed as connectivity expands across the plant.
As a result, traditional security models can’t keep up with interconnected environments. Zero Trust addresses this gap by removing implicit trust and continuously verifying every user, device, and connection - protecting critical operations and uptime.

Understanding Operational Technology & IT in Manufacturing

Modern manufacturing relies on a combination of operational technology systems (OT) and IT systems. OT systems manage physical processes such as programmable logic controllers (PLCs), supervisory control systems, and factory floor equipment, while IT systems handle production data, reporting, and decision-making that support everything from supply chains to predictive maintenance.

Historically, OT and IT operated in isolation, which helped preserve uptime but limited visibility across manufacturing environments. As digital transformation brings these modern systems closer together, security challenges become more complex, making it harder to spot anomalies or prevent unauthorized access before it impacts operations. Ensuring OT and IT work together securely is essential for maintaining operational continuity and improving operational efficiency.

The Evolving Threat Landscape in Manufacturing

Manufacturing companies are increasingly targeted by cyber threats, often because they use legacy systems designed for reliability, not security. OT environments are characterized by their use of specialized equipment and protocols, often with long service lives and no regular updates, leaving them vulnerable. Moreover, the convergence of OT and IT has expanded the attack surface, making it easier to compromise both systems.

Protecting operations means monitoring OT and IT networks in real time, controlling who can access critical systems, including remote access, and applying multiple layers of network security. This approach helps safeguard industrial systems, keep operations running efficiently, and reduce the risk of emerging cyber threats.

Zero Trust Principles for Manufacturing

Modern manufacturing can’t rely on old assumptions that internal systems are safe. The Zero Trust architecture flips that approach: every user, device, and connection is verified before it can access OT or IT systems. By using network segmentation, strict identity verification, and least-privilege access, factories can stop threats from spreading across industrial networks and critical operational systems.

Continuous monitoring, multi-factor authentication, and real-time alerts let security support detect anomalies quickly, while controlled access for remote users and vendors keeps production running safely. This approach reduces operational risks, protects OT security, and ensures key operations continue uninterrupted even under attack.

Implementing Zero Trust in Manufacturing

1. Assess Current Security Posture
   Inventory all assets, including industrial control systems, legacy OT devices, IT systems, and hardware/software systems to identify vulnerabilities and operational threats.
2. Enforce a Unified Architecture
   Create strong security systems by implementing strict access controls, continuous verification of user identity, and network segmentation across OT and IT environments.
3. Continuous Monitoring & Threat Detection
   Deploy real-time monitoring, automated alerts, and anomaly detection across industrial networks to respond swiftly to emerging threats.
4. Protect Operations & Reduce Risk
   This framework reduces the attack surface, protects industrial systems, and ensures operational continuity without disrupting essential manufacturing systems, giving OT teams the tools to act decisively.
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Operational and Security Benefits

A well-implemented Zero Trust model strengthens both OT and IT networks, safeguarding critical assets and industrial systems. Security teams gain visibility into operational systems and hardware and software systems, enabling proactive threat detection and reducing operational risks.

Zero Trust also enhances operational efficiency. Predictive maintenance and supervisory control systems continue to function safely, even during cyber incidents. By aligning security solutions with business objectives, manufacturers can maintain resilience in evolving threat landscapes, protect factory floor operations, and ensure human safety, operational integrity, and uninterrupted production across industrial environments.

Zero Trust as a Manufacturing Imperative

For manufacturing organizations, Zero Trust is more than a cybersecurity framework; it’s a business-critical strategy. By enforcing Zero Trust access, segmenting industrial networks, and continuously monitoring both IT and OT environments, manufacturers can protect critical infrastructure, reduce operational risks, and maintain uninterrupted production.

At Roca Networks, we specialize in helping manufacturing organizations implement Zero Trust security protocols tailored to both OT and IT, ensuring a strong overall security posture that supports long-term growth and resilience in modern industrial operations.