Enhancing Cybersecurity in Food Production: Strategies for Zero Downtime

Key Takeaways:

• Build Resilience Without Downtime: Utilize passive asset discovery, robust network segmentation, and controlled remote access to bolster cybersecurity without halting production.
• Secure Legacy Systems Smartly: Protect older PLCs and SCADA equipment through network isolation and virtual patching, avoiding traditional code changes.
• Empower People as the First Line of Defense: Incorporate quick, role-based cybersecurity training into daily routines to enhance safe behavior.

In the food and beverage manufacturing sector, uptime is paramount. While fortifying operational technology (OT) is essential, plant leaders often face the challenge of implementing these changes without disrupting production schedules or compromising quality. This article outlines practical steps to enhance cybersecurity while maintaining uninterrupted operations.

No-Unplanned-Downtime Security Measures

Effective OT security hinges on a conservative, layered, and invisible approach. According to the U.S. Cybersecurity and Infrastructure Security Agency (CISA), the focus should be on maintaining safety and business continuity through various principles, including segmentation and restricted remote access.

Three Non-Negotiables for Uptime

1. Know Your Assets: Establish an asset inventory without interfering with production. Utilize tools like TAPs and switch telemetry instead of intrusive agents.
2. Segmentation is Key: Employ the ISA/IEC 62443 model to segregate production cells and corporate IT.
3. Control Remote Access: Implement time-bound accounts and multi-factor authentication to maintain vendor access safely.

Why It Works: These actions do not interfere with real-time control systems, allowing production to continue unimpeded.

Securing Legacy Equipment Without Code Changes

Legacy PLCs are prevalent but often challenging to patch quickly. Focusing on compensating controls is essential:

• Ring-Fence Old Assets: Protect legacy systems by situating them behind a dedicated firewall.
• Broker Remote Support: Ensure vendor access is monitored and requires multi-factor authentication.
• Virtual Patching: Employ intrusion-prevention mechanisms until updates can be applied.
• Maintain Manual Operation Modes: Test manual overrides and ensure SOPs are in place.

Conducting Risk Assessments During Maintenance Windows

Objective: Achieve a defensible risk profile without unintended downtime.

Pre-Maintenance Preparation

• Gather an updated view of OT architecture, assets, and data flows.
• Align risk assessments with the NIST Cybersecurity Framework (CSF) 2.0.

Activities During Maintenance Windows

• Passive Network Capture: Monitor network traffic to confirm connections.
• Non-Intrusive Checks: Run diagnostics approved by vendors without risking device stability.
• Safe Patching: Apply pre-tested patches only on non-redundant assets.

Post-Maintenance Review

• Update asset inventory and record any changes made.

Training Frontline Employees Like Food Safety

Human error often leads to cybersecurity breaches. Regular, concise training is imperative:

• Micro-Huddles: Conduct 5-7 minute sessions discussing real scenarios.
• Stop and Verify Culture: Encourage operators to question suspicious activity.
• Role-Based Drills: Run drills tailored to employee functions, referencing realistic attack behaviors.

Vendor Checklist for Security Solutions

• Does the solution enable agentless OT discovery?
• Can it enforce security policies without altering PLC logic?
• How are edge devices protected and monitored?
• What is the product’s security lifecycle for updates?

FAQs: Enhancing OT Cybersecurity Without Slowing Production

Q: Will these steps slow down operators or maintenance?
A: No, when properly implemented, controls are positioned at the network edge and do not disrupt operational flow.

Q: What’s the best approach to legacy PLCs?
A: Implement segmentation, restrict access, and use virtual patching until the next planned downtime.

Q: How often should risk assessments be conducted?
A: Use each scheduled maintenance window to evaluate and update risks.

Cybersecurity doesn’t have to come at the cost of production efficiency. By focusing on asset visibility, strong segmentation, and integrating security into daily practices, plant leaders can navigate the challenges of modern threats successfully. Align with the latest guidance from NIST and CISA to ensure a robust cybersecurity posture.