Navigating Security Challenges Around OT in the DoD’s Manufacturing Lines

How operational technology can revolutionize logistics, supply chain management, and overall efficiency.

Operational technology (OT) is set to transform the Department of Defense's (DoD) manufacturing lines, improving logistics and supply-chain management into a new era of efficiency and reliability. As the DoD embarks on its mission to mobilize military forces and safeguard our nation, the strategic integration of OT within the Defense Industrial Base (DIB) promises operational enhancements. But, as it is more integrated into the DIB, OT introduces new security challenges. 

Ensuring the security of OT systems helps the DoD maintain operational effectiveness, essential to the mobilization, deployment and sustainability of military operations. But the use of legacy systems alongside new technologies creates a unique challenge: a complex and vulnerable supply chain that is a prime target for cyberattacks.

The complexity of OT in manufacturing

Manufacturing processes involve countless vendors, contractors and intricate technology networks throughout the DoD. The DIB encompasses research and development, as well as subsystems and components or parts for military systems. It is a labyrinth of 100,000 domestic and foreign DIB companies providing incidental materials and services encompassing manufacturing facilities, depots, logistics complexes and combat equipment. 

OT is deeply embedded in the DoD’s manufacturing lines, driving industrial process automation (IPA) and manufacturing execution systems (MES). Programmable logic controllers (PLCs), a staple in modern manufacturing, exemplify this integration. IPA, MES and PLCs require protection against internal and external threats. A breach in these systems could lead to severe disruptions in operations, affecting the DoD's readiness and response capabilities.

As manufacturing systems become more complex, they also become more vulnerable to threats. The manufacturing sector has been steadily seeing more attacks in recent years. Manufacturing was the top attacked industry in 2021, reporting 23.2% of the attacks, according to data from IBM’s X-Force. And in 2022, Sophos’ “The State of Ransomware in Manufacturing and Production” report revealed that 66% of manufacturing and production organizations reported an increase in the complexity of cyber attacks, and 61% reported an increase in the volume of cyber attacks when compared to the previous year’s survey. 

DoD manufacturing supply chains and OT

OT can help revolutionize how the DoD operates and manages its manufacturing supply chains. It offers significant opportunities to enhance efficiency, resilience and readiness by automating processes, predicting equipment failure and optimizing energy use. However, integrating OT into the complex DoD ecosystem presents unique challenges that require thoughtful planning and strategic execution. The following use cases illustrate these implementation dynamics:

• Automated supply chain management: OT enables the automation of supply chain processes in manufacturing facilities. Sensors and PLCs can be used to monitor inventory levels, automatically ordering parts when needed. However, integrating these technologies with legacy systems requires careful coordination to avoid disruptions in the supply chain.
• Predictive maintenance: Advanced OT systems can predict equipment failure before it occurs, minimizing downtime. Implementing such systems means a shift from traditional maintenance schedules to a data-driven approach, which can be a significant cultural and operational change for facilities.
• Enhanced quality control: OT can improve quality control on the manufacturing floor using sensors and real-time data analysis. This change demands rigorous data management and analysis capabilities, posing a challenge for facilities lacking in these areas.
• Energy efficiency optimization: OT can optimize energy use in manufacturing processes, leading to savings and reducing environmental impact. However, achieving this requires a deep understanding of both the manufacturing processes and the OT systems, which can be a steep learning curve.

Optimal approaches for DoD manufacturing line integrity

To ensure efficient, secure and reliable manufacturing operations, the DoD needs a solution that protects manufacturing lines from cyberthreats across all OT processes. It should provide compatibility and secure integration between new and legacy systems, and seamlessly allow for the flow of materials and timely procurement and distribution. An ideal OT security solution for the DoD includes features such as:

• Scalability and flexibility: The solution must be scalable to accommodate different sizes and types of manufacturing facilities within the DoD.
• Robust cybersecurity: Given the sensitive nature of DoD operations, robust cybersecurity measures protect against both external and internal threats. This includes advanced encryption, regular security updates and intrusion detection systems.
• Real-time monitoring and control: Monitoring in real-time and control capabilities allow for an immediate response to operational anomalies or security threats.
• Comprehensive data analysis: Tools for comprehensive data analysis aid decision-making, predictive maintenance and process optimization.
• Regulatory compliance: The solution should facilitate adherence to all relevant regulations and standards.

How Tenable OT Security enhances manufacturing line integrity

Tenable OT Security offers a solution that meets the DoD's unique demands. It provides a centralized view of OT and IT assets, crucial for the comprehensive monitoring and management of the entire manufacturing infrastructure. This level of visibility and understanding allows for better detection of vulnerabilities and potential threats, ensuring a secure and resilient supply chain. Tenable's approach to OT security encompasses not just the technological aspects but also safeguards against the potential for human error, ensuring a well-rounded defense against cyber threats.

Tenable OT Security can help the DoD maintain manufacturing line integrity, ensuring efficient, secure and reliable operations. 

To learn more about how Tenable can help you, join us for the webinar “Navigating OT Security in the DoD” on April 16th at 2:00pm ET or read our whitepaper on OT security use cases in the DoD. 

This is the fifth blog in our six-part blog series on OT in the DoD. Below are links to other blogs in this series. 

• Strengthening Cyber Protections in the DoD's OT Systems
• Keep the Water Flowing for the DoD: Securing Operational Technology from Cyberattacks
• Protecting DoD Building Management Systems with Advanced OT Security
• Enhancing Transportation Cybersecurity and Fleet Management for the DoD
• Operational Technology in the DoD: Ensuring a Secure and Efficient Power Grid