Securing Legacy Equipment: Strategies to Prevent Criminal Activity in Manufacturing

On 15 February 2024, Toyota, the world’s largest carmaker, was forced to halt production at all 14 of its plants in Japan due to a system failure caused by a cyberattack. The system outage affected Toyota’s parts supplier, Kojima Industries, disrupting the company’s just-in-time production system.

This attack not only impacted Toyota but also had ripple effects throughout its supply chain, highlighting the interconnected nature of modern manufacturing operations.

This incident serves as a stark reminder of the vulnerabilities faced by manufacturing companies in our increasingly connected world and serves as a wake-up call for the manufacturing sector, emphasising the need for proactive cybersecurity measures to protect against increasingly sophisticated threats.

This blog explores effective strategies to protect legacy equipment from such attacks and maintain a secure manufacturing environment.

Understanding the Risks

Legacy equipment in manufacturing often lacks modern security features, making it an attractive target for cybercriminals. These systems may run outdated software, use insecure communication procedures, or have limited encryption capabilities. Without proper protection, they can serve as entry points for malicious actors seeking to disrupt operations, steal sensitive data, or cause physical damage.

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Key Strategies for Securing Legacy Equipment

Network Segmentation and Isolation

One of the most effective ways to protect legacy systems is through network segmentation. By isolating vulnerable equipment in separate network segments, you can significantly reduce the risk of cyberattacks spreading throughout your organisation. Consider implementing the following measures:

Create separate network zones for legacy systems
Use firewalls and access controls to restrict communication between zones
Implement virtual LANs (VLANs) to further segment network traffic

Implement Strong Access Controls

Limiting access to legacy systems is crucial for maintaining security. Employ the following practices:

Enforce strong authentication measures, including multi-factor authentication where possible
Regularly review and update user access privileges
Implement the principle of least privilege, granting users only the access they need to perform their jobs

Virtual Patching and System Hardening

While legacy systems may not support traditional patching, virtual patching can provide an additional layer of protection. This involves implementing security controls at the network level to mitigate known vulnerabilities. Additionally, harden your systems by:

Disabling unnecessary services and ports
Removing default accounts and passwords
Implementing application whitelisting to prevent unauthorised software execution

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Continuous Monitoring and Incident Response

Implement robust monitoring solutions to detect and respond to potential security incidents quickly. This includes:

Deploying intrusion detection systems (IDS) to identify suspicious activities
Regularly reviewing system logs and network traffic for anomalies
Developing and testing an incident response plan specific to legacy equipment

Data Backup and Recovery

Ensure you have a reliable backup strategy for your legacy systems. Regularly back up critical data and system configurations, storing them securely offline or in isolated environments. Test your restoration processes periodically to ensure you can quickly recover in case of a security incident or system failure.

Employee Training and Awareness

Educate your staff about the unique security challenges posed by legacy equipment. Provide regular training on:

Recognising potential security threats
Following proper security protocols when interacting with legacy systems
Reporting suspicious activities or potential vulnerabilities

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Embracing a Holistic Approach

Securing legacy equipment in manufacturing environments requires a comprehensive strategy that addresses both technical and human factors. By implementing these strategies, organisations can significantly reduce the risk of criminal activity and ensure the continued safe operation of their critical legacy systems.

Remember, security is an ongoing process. Regularly assess your security measures, stay informed about emerging threats, and be prepared to adapt your strategies as the threat landscape evolves. With a proactive approach to security, you can protect your legacy equipment and maintain a resilient manufacturing operation in the face of evolving cyber threats.

This content has been generated with the assistance of artificial intelligence (AI). While AI technology was used to draft and develop the initial content, it has been thoroughly reviewed, edited, and fact checked by Luke to ensure accuracy and relevance. We strive to provide high-quality and trustworthy information, but please be aware that AI-generated content may contain errors or omissions. We take full responsibility for the final content presented here and are committed to maintaining transparency and integrity in our use of AI technology.