Across manufacturing operations, the physical and the digital are converging. Everywhere from factory floors to global supply networks, the growing volumes of data generated by physical hardware, the next generation of 'smart' devices - are in constant flow, allowing for micro and macro views of processes that would previously have been impossible to achieve. When it comes to developing more efficient, cost-effective, and intelligently integrated operations, the possibilities are truly immense.
Secure by Design
But as the sector explores how these new models can be used to bring new innovations to life, it is important that the ongoing challenge of security is not neglected. A recent report revealed that almost half of UK manufacturers had experienced a cyber security breach, with more than 25% of respondents experiencing financial loss as a result. As smart technologies and the IoT continue to establish themselves, a range of new attack vectors will be created across manufacturing operations - all of which bad actors will be ready and waiting to take advantage of.
While all manufacturers will already have both physical and cyber security systems in place, it is time to consider how these can evolve to best serve the new operational models emerging across the sector...
Don't discount the Purdue Model!
Introduced in 1992 by Theodore J. Williams and the Purdue University Consortium, the Purdue Model has long formed the basis of OT security ecosystems for manufacturing operations by providing a robust model for the associated digital workflows. It accomplishes this by dividing the underlying architecture in six distinct 'zones':
- Level 4 / 5: Enterprise zone
The primary network functions that help orchestrate manufacturing operations. - Level 3.5: Demilitarised zone
Firewalls, proxies, and other security systems designed to protect against lateral moving threats. - Level 3: Manufacturing Operations Systems Zone
The OT systems responsible for production workflows, i.e. day-to-day operations on the shop floor. - Level 2: Control Systems Zone
The systems that control and monitor physical processes and manage the data generated. - Level 1: Intelligent Devices Zone
The instruments that control the devices at level 0. - Level 0: Physical Process Zone
The devices that execute a range of physical actions throughout the production process, which may be connected to monitoring systems in the Cloud.
This model has proven its worth for more than thirty years now, supporting the design and delivery of security ecosystems that encompass both IT and OT. However, with the rise of the IoT and smart devices, as well as the increasing speed of Cloud transformation, the different zones can frequently become blurred, which has led some to question whether it is still applicable to modern manufacturing.
We would argue that although data may now frequently travel between several zones at once, the Purdue Model's segmentation still provides a helpful way of understanding the different ways in which data flows across manufacturing operations and -critically - the potential attack vectors that are created as it does so. The new breed of cyber security for manufacturing must build on this well-established approach, along with considering emerging standards like IEC 62443, the zero-trust model, and the NIS-Directive due to come into force in October of this year, in order to ensure the integrity of these complex dataflows.
Agile security for agile operations
Establishing this new model of cyber security will be very much a journey rather than an event - one that requires close collaboration between manufacturers and trusted technology partners who cannot just demonstrate substantial experience within the sector, but also around the successful integration of IT and OT. Vysiion has been a long-time supporter of the manufacturing sector in this regard, working closely with industry leaders to ensure their security ecosystems remain fit for purpose and support the ongoing innovation for which the sector is renowned.
To explore how to optimise the security of your own manufacturing operations, while simultaneously embracing the opportunities opened up by the convergence of IT and OT, do not hesitate to contact us.
Cyber-Secured Engineering
This brochure sets out the Exponential-e Group's pedigree across the CNI sector, and our full range of capabilities, with real-life case studies of our ongoing work with leaders and innovators across the sector.
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With manufacturing now officially incorporated into the UK's CNI sector, its overall levels of resilience and security must be reconsidered, incorporating best practice and technical innovations from other companies from across the sector (i.e. utilities and transport firms).
A key aspect of this will involve expanding manufacturers' definition of resilience beyond the safety and performance of physical machines to the integrity of the growing volumes of data generated on-site, and the cross-site connections that are increasingly powering tomorrow's interconnected workflows.
This is more than just a 'nice to have'. The recently announced Cyber Security and Resilience Bill is just the latest step in governments around the world taking proactive steps to secure public services – and the digital platforms and supply chains that support them – in an increasingly turbulent geopolitical landscape. As we close out Critical Infrastructure Security Month, the need for new standards of security and resilience across the entire CNI sector has never been higher, so let's explore the steps manufacturers can take to proactively establish this across their operations.
Optimising the resilience of manufacturing data lakes
The rise of 'smart' technologies within manufacturing operations is transforming the sector's workflows, but also significantly increasing the volumes of data that must now be stored and managed in full compliance with all CNI regulations, including the Cyber Security and Resilience Bill, EU NIS 2, and eCAF. Storing these large volumes of structured and unstructured data onsite will likely prove impractical, introducing a serious financial and operational burden, but at the same time, the need for real-time visibility of manufacturing operations, along with increasingly complex security and compliance challenges, means a full-scale move to the Cloud will not necessarily be viable.
Colocation offers an alternative way forward here, offering manufacturers a single answer to a range of data hosting challenges. By relocating specific volumes of data to dedicated space in external, geographically dispersed data centres, while keeping others on-site – potentially as part of a wider hybrid Cloud strategy – manufacturers will enjoy a whole new level of flexibility in terms of how they store and manage their data that will, in turn, bring them up to the standards of operational resilience that CNI demands.
Of course, putting all this into practice requires a world-class hosting environment…Enter your text here...
How Vysiion are providing the foundation for more resilient manufacturing across the UK
This is why Vysiion continues to maintain our presence in the Tier III Ark data centres – the Government's hosting environment of choice and the only data centres with pan-government accreditation at all security levels. As an active presence in these highly secure, eco-friendly hosting environments, we have helped organisations across a range of sectors develop approaches to data hosting that support the most complex workflows and compliance obligations, offering hands-on support throughout the migration process to minimise any disruption. This includes connections to the secure private networks utilised across manufacturing operations, where necessary.
Our presence in the Ark data centres, combined with our deep experience around 'smart' technologies, the ongoing convergence of IT and OT, and the manufacturing sector's unique workflows and operational models – plus comprehensive cyber security capabilities – means we are able to help you manage your data in the way that best suits your operations, your budget, and your evolving compliance obligations.
Just contact us if you would like to discuss your own manufacturing operations' data hosting requirements in greater depth.
Cyber-Secured Engineering
This brochure sets out the Exponential-e Group's pedigree across the CNI sector, and our full range of capabilities, with real-life case studies of our ongoing work with leaders and innovators across the sector.
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The Finance sector has always been one of the most dynamic, rapidly evolving industries, and this shows no signs of changing any time soon. But while shifts in the landscape may well open new opportunities, they will also come with new challenges, and it is the organisations who are ready and able to face these head-on who will continue to thrive in the years ahead.
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The past few years have been challenging for the global Manufacturing sector, with both Brexit and COVID-19 creating a wide range of operational disruptions whose impact is still being felt. Indeed, as recently as January 2023, we saw UK manufacturing shrinking for the sixth consecutive month1.
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Manufacturing workflows are evolving at an unprecedented rate, and the trend shows no signs of slowing down. The increasing effectiveness and affordability of 'smart' technologies and the Internet of Things means IT and OT are increasingly interconnected, with increasing volumes of data flowing between sites and devices on an ongoing basis.
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Effective manufacturing workflows are all about doing things more efficiently - from the simplest tasks to the most complex. While this is an ostensibly simple concept, the increasingly interconnected, global nature of modern manufacturing workflows hides a number of challenges, with even the briefest period of downtime potentially costing thousands of pounds, particularly during periods of increased consumer demand.
However, the increasing sophistication of artificial intelligence (AI) and 'smart' technologies offers a rich vein of opportunities here, allowing routine processes to be automated, where possible and appropriate. Not only will this significantly improve the overall efficiency of manufacturing processes, if successfully executed, it will lead to long-term cost savings and free staff to focus their attention on activities that will lead to fresh innovations and sustainable business growth.
With that in mind, let's consider where AI-powered automation can be of most use across manufacturing workflows…
Streamlined, proactive maintenance processes
The rollout of interconnected sensors at manufacturing sites ensures any faults can be automatically tracked, identified, and escalated to the appropriate team, ensuring the resulting downtime can be kept to the absolute minimum. Beyond ensuring a swift response to any unexpected faults, collating the data generated by these sensors and applying machine learning technologies will allow any trends to be identified and routine maintenance processes adapted accordingly, helping to resolve potential faults before they occur and ensuring costly downtime can be avoided altogether.
And, as a bonus, this will help reduce machines' energy consumption in the long term, further reducing costs and bringing manufacturers another step closer to achieving their environmental goals!
Stress-free quality control
Even the most stringent quality control processes are vulnerable to human error, but AI will not only offer a greater level of consistency, but also allow products to be examined with a level of detail that would be impossible otherwise, particularly for especially small or complex products (computer chips, for example). This way, even the most miniscule defects can be quickly identified before products reach customers, even during the busiest production cycles.
Maximum control and visibility of global supply chains
The vast range of materials utilised across manufacturing operations that must be sourced from around the world means that supply chains are inherently complex. This means there is huge potential for disruption and, in turn, downtime if any area of the supply chain fails. But just as with the machines on factory floors, AI and smart sensors allow for micro and macro views of manufacturers entire supply chains, covering everything from vehicles to individual parts. By monitoring this data and implementing effective analytics, potential disruptions can be predicted and factored into project timelines.
Developing safer factory floors
Finally, amidst all the excitement about the possibilities offered by AI, let's not forget the people who continue to drive effective manufacturing operations! The smart sensors deployed across factory floors can be complemented with wearable sensors for employees. This will ensure the risk of injury from machinery is minimised, while simultaneously supporting wider health & safety initiatives, and thus helping maintain a safer working environment. For example, in environments where employees may be required to lift heavy objects, the data generated by the wearable sensors can be used to avoid injuries by ensuring correct procedures are followed when doing so.
This is all just scratching the surface of what AI-powered automation can potentially offer manufacturers. Leaders across the industry are already exploring the full potential of these technologies, with the support of trusted technology partners, so new opportunities and innovations are sure to keep revealing themselves in the months and years ahead. As we're already seeing in our own ongoing work with manufacturers across the UK, the rise of AI shows no signs of slowing down, so don't hesitate to contact us if you'd like to discuss how it can transform your own operations. It's an exciting time for the entire sector, and we look forward to exploring it with you!
View our Manufacturing brochure
Delivering the digital foundation for tomorrow's manufacturing workflows.
Discover our full portfolio of digital innovations for Manufacturing, and how we are working with leaders across the sector to support the ongoing convergence of IT and OT, the deployment of 'smart' technologies, and the implementation of tomorrow's connected workflows.
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