Industrial Cybersecurity: Protecting Your SDM Systems

Software-defined manufacturing (SDM) helps production run smarter and faster but also introduces the need for stronger industrial cybersecurity.

Every machine and connection is a potential vulnerability, and your data is now a target.

It takes an average of 194 days to identify a breach. That’s more than six months where attackers could exploit your systems, steal your data, and disrupt your operations.

Cyberattacks have risen 41% since 2020, with 65% of manufacturers reporting ransomware attacks in 2024. The average cost to recover from a ransomware attack was $1.67 million, a roughly $60,000 increase since 2023.

With the potential for these significant losses, many manufacturers are tightening the security of their SDM systems.

This article explores how to secure your SDM without impacting production speed or quality.

What is SDM?

SDM is an approach to modernizing manufacturing. It changes traditional manufacturing processes by relying heavily on software to control and optimize production.

In traditional setups, each machine and process is rigidly defined. It often involves significant downtime and cost if you need to make a change.

SDM, on the other hand, is dynamic. Its processes are controlled by a layer of software that can be updated or reconfigured without altering the physical machinery.

For example, an automotive manufacturing plant might use robots to assemble vehicles. In a traditional setup, those robots are programmed for a specific make and model.

If a new model is introduced, the line might need physical reprogramming and retooling.

In SDM, the software sends new instructions to the robots, allowing them to adapt instantly to the new design. Very little physical intervention is needed.

SDM and Its Vulnerabilities

In SDM, everything in a factory—machines, sensors, robots, and even the software that controls them—is connected and often reliant on external systems like the cloud or IoT devices. While this interconnected environment ensures smooth operations, it also introduces new vulnerabilities.

A single weak point can give attackers a way to access the entire system or cause a wider failure. Since all components are linked, a breach in one area, like a compromised IoT sensor or an unpatched software system, can cascade into a larger issue that could potentially halt production.

Once they’re in your system, attackers often seek your data. SDM is dependent on data for decision-making and optimization. If this data is stolen, manipulated, or deleted, it can lead to poor decisions, faulty products, or complete operational failure.

Production metrics and proprietary designs are prime targets.

Attackers look for this type of data to exploit for financial gain, either holding it for ransom or selling to competitors. Without the right protection, your innovation could become someone else’s profit.

Attackers can also target the software and change parameters, which means potentially endangering end-users or workers.

How Cybersecurity Protects SDM

Building a secure and resilient SDM environment requires a systematic approach to cybersecurity.

Step 1: Build a Secure Foundation

Every secure system starts with a strong foundation. Without addressing fundamental vulnerabilities, advanced measures can only go so far.

Conduct Risk Assessments: Your first task is to evaluate the risks in your environment. Prioritize fixing these weak spots based on the potential impact of a breach.

For instance, detecting outdated firmware on operational technology (OT) systems—a common issue—allows you to patch security holes before they become entry points for cybercriminals.

Segment Networks: Your IT systems, which manage data, and OT systems, which control machinery, should not coexist on the same network. Segmentation creates clear boundaries, preventing an attacker who breaches one system from accessing the other.

Secure Access: Role-based access controls ensure that users can only perform actions relevant to their roles. Multi-factor authentication (MFA) adds another layer by requiring additional verification beyond a password.

Regularly Update Systems: Attackers frequently exploit vulnerabilities in outdated software and hardware. Timely installation of patches and updates helps close those vulnerabilities.

Step 2: Fortify Day-to-Day Operations

With a secure foundation in place, the focus shifts to daily practices that keep your defenses strong and adaptive.

Monitor Continuously: Live monitoring tools continuously scan for unusual activity. Whether it’s a spike in data traffic or an unexpected login attempt, these tools alert you to anomalies before they escalate.

Train Employees: Your workforce is often the first line of defense against cyber threats. Training employees to recognize risks—like phishing emails or suspicious downloads—reduces human error, which remains a leading cause of breaches.

Backup Data: Reliable backups are your safety net. Regularly back up important data and store copies in secure locations, like the cloud or offsite. Backups enable you to restore operations in the event of a ransomware attack or hardware failure.

Limit Vendor Access: Third-party vendors often need to interact with your systems, but their vulnerabilities can become yours. Limit their access to only what’s necessary and enforce strict security protocols, like using encrypted connections and verifying credentials.

Step 3: Implement Advanced Defenses

With your operations fortified, it’s time to implement advanced measures that anticipate and prevent sophisticated threats.

Adopt Zero Trust Principles: Zero trust means that every device, user, and connection must prove its legitimacy before gaining access, regardless of whether they’re inside or outside your environment.

In SDM, this approach limits the scope of breaches, even if one part of the system is compromised.

Encrypt Communications: Data moves constantly in SDM—between devices, systems, and cloud platforms. Encryption ensures that even if attackers intercept the data, they can’t read or alter it.

For example, encrypting communication between production systems and centralized controllers prevents tampering with machine instructions.

Use Intrusion Detection Systems (IDS): IDS tools scan your network for signs of unauthorized activity, like repeated failed login attempts or abnormal data transfers.

When anomalies are detected, the IDS sends alerts, enabling your team to respond immediately. The IDS can be integrated with OT systems to monitor activity without disrupting production.

Plan for Incident Response: No system is invincible, so prepare for the worst. An incident response plan outlines how to contain, investigate, and recover from attacks.

Cybersecurity Is a Necessity, Not an Option

As manufacturing moves towards a software-driven scenario, the risks of cyberattacks grow alongside the opportunities.

A resilient manufacturing environment is one that can anticipate, detect, and recover from threats.

By adopting robust cybersecurity practices, you’re investing in the future of your business. Proactive measures today will protect your systems and customers from the growing threats of tomorrow.

The path forward is clear: secure your foundation, fortify your operations, and build a system that can adapt to challenges without compromising your goals.

If you desire to take the next step in securing your manufacturing systems, Taazaa can help. As a leading software development company specializing in manufacturing software development, we understand the challenges of SDM.

Contact us today to explore how we can strengthen your manufacturing environment and prepare your business for a secure future.