In the era of digitalization, technology that was once groundbreaking can quickly become outdated. Floppy disks, fax machines, and dial-up internet are just a few of the digital dinosaurs we’ve eagerly left in the dust in favor of more agile and efficient alternatives. Unfortunately, the opposite is also true – solutions and processes that should be left in the past simply aren’t. 

A great example is the “air gap.” Once considered a gold standard of security in which systems were physically isolated from outside networks, the air gap has become less effective amid the rise of digital systems that rely on real-time data, cloud integration and seamless communication between information technology (IT) and operational technology (OT). 

As Erik Gross, Deputy Chief Information Security Officer at QAD, pointed out in a recent article, the shift from isolated systems to interconnected technologies demands a rethinking of security measures. Modern threats don’t just exploit systems – they exploit people. And in manufacturing environments with shared devices and high turnover, outdated security strategies like the air gap can’t keep up. 

Are outdated security tactics like the air gap holding back your operations? Let’s explore how adaptive security strategies built for today’s interconnected world can better protect your people, processes and equipment. 

Why the Air Gap No Longer Works

Separating systems from external networks via the air gap used to be an effective tool for preventing unauthorized access. However, automation, the Industrial Internet of Things (IIoT) and other advances have created vulnerabilities that are no match for an old-school system of defense. 

A recent National Institute of Standards and Technology (NIST) report highlights the evolving nature of cyber threats, noting that some types can now invade air-gapped systems. Modern malware, for example, can be introduced through compromised USB drives or wireless signals that bypass physical barriers yet are critical for a high level of connectivity. 

As Erik explained, this challenge is not unique to manufacturing. Industries like healthcare and education, where shared devices are common and workers are assigned digital identities, face similar issues. The need for secure, efficient and adaptable solutions is universal and reminds us that businesses need to not just think in terms of technology, but also how they manage human-driven vulnerabilities. 

Managing the Human Element in Manufacturing Cybersecurity

People are the most important part of any organization, but they can also be one of your greatest cybersecurity vulnerabilities. In 2023, the World Economic Forum reported that nearly 95% of cybersecurity breaches are linked to human error. The human element of cybersecurity cannot be overlooked, but it’s particularly complex in manufacturing where high turnover rates and temporary workers can complicate access management. 

People-centric challenges include:

• Managing identities: Workers require quick yet secure access to cloud-based systems and external applications, yet forgotten passwords and compromised credentials can present a cybersecurity vulnerability.
• Shared devices: Tracking and securing individual access is easier said than done in manufacturing environments where shared devices are commonplace. Without stringent oversight, unauthorized access can easily go undetected. 
• Temporary or seasonal workers: No manufacturer wants a high turnover rate but it’s unavoidable in some sectors, especially with seasonal ebbs and flows in demand. Temporary credentials can create an entry point for cyber criminals. 

To complicate matters further, modern manufacturers need security solutions that not only safeguard their systems and adapt to the shifting workforce, but are also easy for people to use and for IT teams to maintain.

Adaptive Strategies for Modern Manufacturing Security

Business leaders often rely on outdated solutions and processes because “that’s the way things are done” or “don’t fix what isn’t broken” but that mindset poses a significant risk – especially when it comes to cybersecurity. Modern, interconnected manufacturing systems require an approach to security that’s equally sophisticated, and implementing adaptive security strategies may be easier than you think. 

Erik shared several approaches for safeguarding digitized manufacturing environments, including:

Access Control

A relatively simple approach to cybersecurity, access control involves three pillars: something you know (a password), something you are (biometric data), and something you have (a security token). Gloves, hardhats and safety gear in manufacturing, however, can complicate the biometric component. In these cases, flexible access solutions, like temporary to time-based controls, may be an effective alternative. 

Multi-Factor Authentication (MFA)

MFA is an increasingly popular tool for restricting unauthorized access that involves using multiple verification factors. It is so effective, in fact, the Cybersecurity and Infrastructure Security Agency (CISA) reported that MFA reduces the risk of being hacked by 99%. Manufacturers considering MFA should focus on employee education to ensure a high adoption rate.

Automating Digital Access Control

Your production line is likely automated by now – shouldn’t your approach to cybersecurity be too? This methodology is known as digital access control and involves automating processes like onboarding and credential management to ensure employees have access when and where they need it without overburdening IT teams. It also eliminates inefficient manual processes, liberating your IT team to focus on other priorities. 

Securing the Future of Manufacturing

The air gap, once a tried-and-true measure, is no longer sufficient in today’s interconnected manufacturing environments. As systems continue to become more integrated, relying on outdated strategies – or digital dinosaurs – creates cybersecurity vulnerabilities. The solution? Embrace modern, agile security strategies that are just as adaptive as the future-proof enterprise you’re building. 

Don’t wait for a breach to realize the gaps in your defenses. Take action now, and read Erik’s full article to learn more.