Cyber Intrusions Are Surging in Manufacturing: Here’s What You Need to Know

Cyberattacks on manufacturing plants are climbing at an alarming rate—and the consequences are hitting the industry where it hurts most: uptime, contracts, and reputation.

According to the 2024 State of OT and Cybersecurity Report, nearly one-third of organizations experienced six or more cyber intrusions in the past year. Just two years ago, that number was only 11%. For manufacturers, this spike isn’t an abstract statistic—it’s a direct threat to operations on the plant floor.

Why Manufacturing Is a Prime Target

Manufacturing environments are a unique mix of old and new. You’ve got legacy OT systems designed to last decades running side by side with modern ERP platforms, cloud services, and connected IoT devices. That mix creates complexity—and attackers thrive in complexity.

• High cost of downtime: Every minute of halted production can cost thousands of dollars. Criminals know manufacturers are more likely to pay ransoms to get back online quickly.

• Thin margins: With profitability already under pressure, absorbing unplanned costs from a cyberattack is especially painful.

• Supply chain pressure: A single delay doesn’t just impact your plant—it cascades through vendors and customers relying on your timelines.

It’s no wonder manufacturing has become one of the top industries targeted by ransomware and phishing campaigns.

The Attack Methods Hitting Manufacturing the Hardest

The report showed a sharp increase in certain types of intrusions:

• Phishing and business email compromise: Over 75% of organizations reported phishing attempts, and 65% experienced compromised business email. In a plant environment, one wrong click from a floor manager or procurement officer can expose vendor contracts, schematics, or payment details.

• Ransomware and wipers: More than half of respondents reported ransomware incidents this year—up from just one-third last year. Attackers know manufacturers face enormous pressure to restore operations quickly, making them more likely to pay.

• Web and mobile breaches: With remote access and connected devices now common in industrial environments, attackers are finding new pathways into networks.

For manufacturers, these aren’t “IT problems.” They’re production problems.

The Fallout: More Than Just Lost Data

When manufacturers think about cybersecurity, they often focus on stolen data. But the impacts go far beyond files and records:

• Production shutdowns: Machines sit idle while teams scramble to contain the intrusion.

• Contract penalties: Missed delivery deadlines mean lost customers and broken relationships.

• Brand damage: Over half of companies in the report saw their reputation take a hit after a breach. In a competitive market, trust is everything.

• Compliance risks: Failing to protect OT data can trigger fines or lost certifications, especially for ISO- or NIST-regulated operations.

In other words, a cyber intrusion in manufacturing isn’t just an IT incident—it’s a business crisis.

How Manufacturers Can Fight Back

Stopping every attack isn’t realistic, but manufacturers can take smart, industry-specific steps to reduce their risk:

• Harden email defenses with advanced filtering to block phishing before it reaches staff.

• Segment networks so IT and OT aren’t directly connected, limiting attacker movement.

• Train plant staff to spot suspicious activity—because human error is still the top entry point.

• Develop a tested incident response plan that includes production systems, not just office IT.

• Monitor OT and IT environments 24/7, catching small issues before they become plant-wide shutdowns.

How TotalCare IT Helps

At TotalCare IT, we’ve seen firsthand how Idaho manufacturers are being targeted. Our team specializes in securing plant floor technology, ERP systems, and supply chain data with a mix of proactive monitoring, secure backups, and compliance-focused controls.

We don’t just provide IT support—we help manufacturers keep their production lines running, protect sensitive data, and safeguard their reputation.

Don’t Wait for an Intrusion to Shut Down Your Plant

If you’re a manufacturer worried about the rising wave of cyberattacks, now is the time to act. The cost of prevention is a fraction of the cost of downtime.

Schedule a quick 15-minute call with TotalCare IT. Let’s build a cybersecurity strategy that protects your operations, your contracts, and your bottom line.