Estimated reading time: 4 minutes
Manufacturing cybersecurity now commands board attention. Rockwell Automation’s 10th “State of Smart Manufacturing” places cyber threats second among external risks, after economic conditions. Our coverage earlier this week highlighted extreme Operational Technology (OT) loss models nearing $330 billion. Business interruption alone could exceed $172 billion. The stakes for plants and insurers keep rising. Smart manufacturing security matters.
“As IT and OT become more connected, the attack surface is expanding. Our latest research confirms what we’re seeing firsthand: Cyber risk is now one of the top threats to manufacturing growth. You can’t protect tomorrow’s enterprise with yesterday’s tools,” said Stephen Ford, vice president and chief information security officer at Rockwell Automation.
Quick Takeaway
- Cyber risk jumps to No. 2 external threat. Thirty percent cite cybersecurity as a top external risk, behind inflation and economic growth at 34%.
- AI adoption accelerates inside security. Sixty-one percent of cybersecurity and IT leaders plan to deploy AI/ML within 12 months—12 points ahead of general manufacturing.
- Data powers defense. Thirty-eight percent will leverage existing data streams to strengthen protection.
- IT/OT hardening takes priority. Forty-eight percent of cybersecurity professionals name securing converged architectures as a five-year success driver, versus 37% overall.
- Cyber readiness becomes a core skill. At companies with $30B+ revenue, 53% rate cybersecurity practices and standards “extremely important,” compared with 47% across all respondents.
AI Plans Surge Across Security Teams
The Rockwell report surveyed 1,560 decision-makers across 17 major manufacturing countries. Roles ranged from managers to the C-suite. Respondents represented diverse industries, including semiconductors, automotive, food and beverage, life sciences, and energy. Company revenues spanned $100 million to over $30 billion.
Regarding Artificial Intelligence and Machine Learning, the report finds that sixty-one percent of cybersecurity and IT leaders plan to adopt AI or ML within 12 months. That pace outruns general manufacturing plans. Teams seek real-time detection and faster response. Leaders also target uptime preservation and safer recovery windows.
IT/OT Convergence Expands the Attack Surface
The integration of factory systems and enterprise IT continues. Nearly half of cybersecurity professionals have prioritized securing converged architectures over five years. Manufacturers also plan to use current data sources for defense. Thirty-eight percent expect data-driven protection to expand.
“You can’t protect tomorrow’s enterprise with yesterday’s tools.“
Stephen Ford, Rockwell Automation
Cybersecurity and Quality Anchor AI Use Cases
Quality remains a leading AI application. Half of respondents plan AI or ML for quality control this year. Cybersecurity follows closely. Forty-nine percent plan AI for threat detection and response. These use cases align with resilience goals and regulatory expectations.
Data Becomes a Defensive Asset
Manufacturers collect more data than ever. Less than half use it effectively today. Many now apply telemetry to security analytics. Thirty-eight percent use device, process, and system data for cyber protection. Another share monitors supply chain risk with similar datasets.
Talent Gaps Pressure Security Maturity
Workforce shortages persist. Organizations elevate cybersecurity and analytical skills in hiring. Large enterprises place even greater weight on standards and practices, and training and role redesign feature in 2025 staffing plans. Many expect to repurpose workers into higher-value digital roles.
Investment Momentum Builds Despite Obstacles
Eighty-one percent say external and internal pressures accelerate digital transformation. Cloud software and AI lead technology investments. Quality and cybersecurity round out the top four. Manufacturers pursue faster ROI and scalable deployments across plants and lines.
Insurance Lens: OT Incidents Drive Outsized Loss
Operational technology incidents can idle production at scale. Losses cascade through suppliers and customers: underwriters now probe network segmentation, remote access control, and recovery drills. Strong manufacturing cybersecurity programs can influence coverage terms. Clear evidence of monitoring and response maturity can support limits and pricing.
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Near-Term Actions for Plant Defenders
Start with an asset map of critical OT systems. Tighten identity controls and network segmentation. Test backups and restoration for control environments. Pilot AI-assisted detection with guardrails and metrics. Track mean time to detect and recover across sites. Align improvements to policy renewals and board risk targets.
Leadership Signals from Rockwell
Executives call cybersecurity a business enabler. Security enables transformation with confidence. AI features in modern security stacks across plants. The message is direct. Yesterday’s tools cannot protect tomorrow’s enterprise.
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