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Industry

Manufacturing and industrial

Manufacturing carries two networks with incompatible requirements. The office wants everything current and patched. The shop floor runs controllers the machine vendor validated against an operating system from a decade ago and will not support otherwise. Nearly every decision here follows from holding those apart properly.

The control that matters most

Segmentation

between office and production

It does not prevent a compromise. It decides whether the cost is one workstation or a week of output.

Six systems, two very different worlds

Manufacturing technology layers and their characteristics
SystemDomain
ERP and MRPRuns scheduling, inventory and costing. Downtime stops planning, not just paperworkBusiness
Shop floor controllersMachine PCs running operating systems the vendor will not let you patchOperational
CAD and engineeringLarge files, heavy workstations, valuable intellectual propertyBusiness
Quality systemsOften required to be retained and auditable by customer contractBoth
Plant networkFrequently flat, which means a compromised office laptop can reach a machineOperational
Customer data exchangeDrawings and specifications from customers, sometimes carrying flow down obligationsBusiness

Five reasons to segment

  • Machine controllers cannot be patched, so containment is the only available control
  • A ransomware event that reaches the shop floor stops production, not just administration
  • Customer security addenda increasingly require separation between office and production networks
  • Defence supply work brings scoping requirements that are far cheaper to meet in a segmented environment
  • Vendor remote access for machine support should reach the machine and nothing else

Segmentation is rarely a large project in a business of this size. It is usually switch configuration, firewall rules and a decision about vendor access, done in stages so production never stops.

Vendor remote access

Machine vendors need to reach their equipment for support, and the arrangements they propose are frequently alarming: a permanent open connection, a shared credential used across their whole customer base, or remote software installed on a machine that also sits on your main network.

The workable version gives the vendor access to their machine and nothing else, on request rather than permanently, with the session logged. Vendors accept this readily when asked. They simply propose the convenient version first because most customers accept it.

This is one of the more common findings in a plant assessment and one of the easier things to fix.

Common questions

Answered before you ask.

Our machine vendor says we cannot update that PC. What do we do?

That is a normal and legitimate constraint. Machine controllers are frequently validated against a specific operating system version and updating them voids support or breaks the machine. The answer is not to update it, it is to isolate it: a restricted network segment that limits what the controller can reach and what can reach it, with vendor remote access scoped to that segment alone. The unpatched system remains, but the exposure is contained and documented as a compensating control.

Is our shop floor really at risk from a ransomware attack?

If the plant network is flat, yes, and this is how manufacturing incidents typically escalate. The initial compromise is nearly always in the office environment, through email or a credential. What determines whether it becomes a production shutdown is whether anything stops it travelling from a desk to a machine. Segmentation does not prevent the initial event. It decides whether the event costs you a workstation or a week of output.

We supply defence primes. Does that change our IT requirements?

It usually does, and the requirements flow down whether or not you contract with the government directly. If a prime sends you controlled technical data, obligations attach to how you handle it. Pierce County has a dense supplier base around Joint Base Lewis McChord and this catches out a lot of machine shops. The first step is asking your primes in writing what flows down to you, because scoping this correctly is what determines the cost of everything after it.

How do you handle maintenance without stopping production?

Office systems are maintained on a normal cycle. Anything touching production is scheduled around shift patterns, staged one cell or line at a time, and done with the machine vendor reachable where their software is involved. Where a plant runs continuously, that usually means planned changes during a scheduled shutdown rather than a weekly window, which makes the annual maintenance calendar a genuinely important document.

Find out whether your plant network is actually flat.

The assessment maps what can reach your machine controllers today. Most manufacturers are surprised by the answer.

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