Manufacturers only have two options with legacy hardware and software — adapt or upgrade. Older machinery and programs have too many security gaps to leave untouched, especially in data-driven environments that Industry 4.0 and 5.0 embrace. IT experts and industry stakeholders must collaborate to reinforce operational technology (OT) systems, even if implementing new equipment occurs in the future. Many strategies consider the sector’s most significant challenges while preserving critical infrastructure and workflows.
1. Lack of Visibility
Most legacy OT systems are isolated and require hands-on interactivity or manual oversight to determine their health and performance. Checking cybersecurity status and data logs is challenging, and attention cannot come from remote environments. Modern systems use sensors and other connected devices to enable enhanced oversight, making it more straightforward to detect incidents before they exacerbate.
Network monitoring tools are available, even for outdated systems. Some are even specifically designed for OT. Combine this with passive monitoring to compensate for the lack of more modern tools, especially as industrial OT becomes a larger target for threat actors.
2. System Age and Patching
Legacy OT technologies may no longer have third-party cybersecurity support. Resources are diverted to modern equipment and products, demanding greater attention than systems companies deem obsolete.
This means hardware and software are vulnerable to novel threats, with no incoming patches to protect against them. Hackers know they can take advantage of these end-of-life exploits because organizations neglect patching. It could lead to compatibility issues, in addition to other concerns like data extrication.
IT teams can still institute internal virtual patching solutions and middleware. These can temporarily address backdoors and vulnerabilities, especially when their company is undergoing digital transformation. Protecting OT while changes occur is as crucial as ensuring new systems are well-defended upon installation. These often strengthen defenses without compromising the OT’s effectiveness.
3. Network Segmentation
Threat actors often enter legacy OT systems to encourage lateral movement among the attack surface. They are connected to countless other machines and programs, letting these hackers move from the OT mechanisms into numerous locations without a struggle.
While modern devices are connected through the internet and other communication protocols, there are ways to segment systems to make them harder to access. This is less common in legacy infrastructure. Sufficient segmentation is essential to prevent malicious activity from spreading with solutions like:
- Firewalls
- Access controls
- Disconnected hardware
- Virtual local area networks
Analysts should institute multiple barriers, as they only reinforce each other.
4. Authentication and Access Control
Unauthorized access is common in older OT tech for several reasons. Many have default credentials that have never been changed, or employees use outdated password creation practices. Some may not include modern verification techniques, which have become standardized and required. Team members may also share accounts, creating more opportunities for compromises like social engineering.
To prevent these entry attempts in legacy OT, staff can establish new login and access controls precedents. Robust password policies should follow modern compliance frameworks. Additionally, IT teams can schedule changes to keep them complex and fresh. Enabling peripherals like multifactor authentication, even as a third-party tool, will force people to interact with a security-first environment regularly and adapt to higher protective measures. Other options include:
- Least-privilege controls
- Zero-trust architecture
- Centralized identity and access management
- Data and credential minimization
Weak or default passwords, shared accounts, and a lack of multi-factor authentication are common in legacy OT environments, making it easier for attackers to gain unauthorized access.
5. Integration with IT
Manufacturers are slowly moving into more connected environments, weaving operational tech with informational. While this is ideal for streamlining workflows and promoting long-term productivity gains, it can lead to an expanded surface area. One could jeopardize the other, becoming catastrophic for more aspects of the facility than if they had not been connected previously.
OT and IT networks are safer in a demilitarized zone. The setup diverts traffic to specific locations without disrupting their ability to work synergetically with each other. Methods include incorporating a strong firewall and leveraging deep packet inspection to redirect requests as necessary, stopping suspicious access attempts.
6. Specialized Skills
Some manufacturers are behind in adopting Industry 4.0 and 5.0 practices for several reasons. Several facilities may be overcoming concerns such as material availability or supply chain inconsistencies that prevent them from allocating resources to OT upgrades.
There may also be skills gaps, with 91%-94% of manufacturing and construction workers reporting a lack of security awareness. Tenured staff may be unfamiliar with how to use new OT machinery and programs, compromising efficiency. If experienced professionals feel less prepared in a previously comfortable environment, it could also damage morale. Facilities may lack the general expertise to adopt new systems, which may justify the need to continue with legacy products.
However, countless security training professionals and agencies are available to educate manufacturers. This can happen gradually, gently upskilling staff of all levels and experience. It mends digital literacy gaps while asserting how urgent cybersecurity is for quality and operational safety. Partnering with experts ensures accurate, applicable information for niche industries.
7. Operational Impact
IT teams in facilities are reluctant to implement any of these changes because they could lower efficiency. Operations may experience more downtime or connectivity issues. Affording these pauses is a challenge, especially if they are already experiencing operational shifts.
Fortunately, teams can schedule times to implement security controls so they do not threaten the highest-value production. They can also test issuing security controls in non-production spaces to simulate the impacts. Then, they can plan based on the anticipated effects to lessen the severity of operational disruptions.
Legacy Equipment With Modern Measures
Countless enterprises still rely on legacy systems out of necessity, but that does not mean they have to go unprotected from novel cybersecurity threats. Stakeholders must collaborate with IT teams and cybersecurity experts to implement temporary solutions for safeguarding OT systems until upgrades are possible. Doing so defends companies against the rising threat of cybercriminals and their innovative tactics, which is crucial for maintaining competitiveness, protecting employees and establishing corporate stability.
