The Growing Ransomware Threat in Manufacturing

Ransomware is no longer just an IT problem; it’s a direct threat to your manufacturing operations. In 2025, the manufacturing sector remains the top target for ransomware attacks, with a 47% spike in incidents reported last year. These attacks don’t just lock up data; they halt production lines, disrupt supply chains, and cost millions in downtime and recovery. For plant managers, OT engineers, and CISOs, securing operational technology (OT) and Industrial Internet of Things (IIoT) systems is critical to keeping your facility running smoothly.

At Shieldworkz, we understand the unique challenges of industrial cybersecurity. The convergence of IT and OT systems, coupled with the rise of cyber-physical systems, has expanded the attack surface. Hackers exploit outdated equipment, unsecured IoT devices, and weak network segmentation to infiltrate critical infrastructure. This blog post dives into the latest ransomware threats targeting manufacturing, why OT systems are vulnerable, and how Shieldworkz’s tailored solutions can help you defend your operations. Ready to protect your plant? Let’s explore practical steps to fortify your OT security in 2025.

Why Manufacturing is a Prime Target for Ransomware

Manufacturing is the backbone of global economies, but its reliance on interconnected systems makes it a magnet for cybercriminals. Here’s why your OT systems are in the crosshairs:

• Economic Impact: Manufacturing’s low tolerance for downtime makes it lucrative for attackers. A single hour of halted production can cost hundreds of thousands of dollars.

• Legacy Systems: Many OT systems, like SCADA and PLCs, were designed decades ago without cybersecurity in mind. These unpatched, outdated assets are easy prey for ransomware.

• IT/OT Convergence: The integration of IT and OT through IoT industrial security creates new vulnerabilities. Unsecured IoT devices, such as sensors or cameras, can serve as entry points.

• Geopolitical Tensions: State-sponsored groups, like APT41, target manufacturing to steal intellectual property or disrupt critical supply chains, especially in sectors like aerospace and defense.

• Ransomware Surge: In 2024, ransomware attacks on the industrial sector surged by 87%, with manufacturing accounting for 71% of incidents.

How Ransomware Exploits OT Systems

Ransomware doesn’t just encrypt files; it can cripple your entire operation. Understanding how attackers infiltrate OT systems is the first step to building a robust defense. Here’s how they get in:

Common Attack Vectors

• Phishing and Social Engineering: Employees are tricked into clicking malicious links or downloading infected files, granting attackers initial access to IT systems that connect to OT networks.

• Unsecured Remote Access: Remote Desktop Protocol (RDP) and VPN vulnerabilities are exploited to gain entry. For example, the PARASITE threat group targeted VPNs in 2024.

• USB Devices: Malware-laden USB drives, often used for maintenance, spread ransomware to air-gapped OT systems.

• Exposed IoT Devices: IIoT devices with default credentials or outdated firmware are easily compromised. Hacktivist group Hunt3r Kill3rs exploited Unitronics PLCs in 2024, targeting renewable energy and water facilities.

• Supply Chain Attacks: Third-party vendors with weak security can introduce ransomware, as seen in the Crowdstrike incident that exposed supply chain vulnerabilities.

Real-World Impact

In 2024, the VARTA Group, a German battery manufacturer, suffered a ransomware attack that shut down five plants, disrupting production for weeks. Similarly, the Cl0p ransomware group caused widespread disruptions in manufacturing and energy sectors in early 2025. These incidents highlight the devastating consequences of OT ransomware, from production halts to supply chain chaos.

Why OT Systems Are Vulnerable

OT systems are uniquely challenging to secure. Unlike IT environments, where rapid patching and updates are standard, OT systems face constraints that make them ripe for exploitation:

• Legacy Infrastructure: Many OT devices run on outdated operating systems (e.g., Windows XP) that no longer receive security updates.

• Operational Continuity: Patching or rebooting OT systems risks downtime, so updates are often delayed or skipped.

• Complex Networks: The convergence of IT, OT, and IoT industrial security creates a sprawling attack surface with poor visibility.

• Lack of Segmentation: Many facilities lack proper network segmentation, allowing ransomware to spread from IT to OT environments.

• Insufficient Expertise: OT engineers often lack cybersecurity training, and IT teams may not understand OT-specific protocols like Modbus or DNP3.

These vulnerabilities make critical-infrastructure defense a priority. Without proactive measures, a single breach can cascade across your entire operation.

Shieldworkz’s Approach to Industrial Cybersecurity

At Shieldworkz, we specialize in securing cyber-physical systems and protecting manufacturing operations from ransomware. Our comprehensive OT security solutions address the unique challenges of industrial environments. Here’s how we help:

1. Asset Visibility and Inventory

You can’t protect what you can’t see. Shieldworkz deploys advanced discovery tools to create a real-time inventory of all OT and IIoT devices, identifying legacy systems, unpatched vulnerabilities, and misconfigurations.

• Why It Matters: Over 70% of manufacturers lack a complete asset inventory, leaving blind spots for attackers.

• Shieldworkz Solution: Our platform maps your entire OT network, providing visibility into devices, connections, and potential risks.

2. Network Segmentation

Proper segmentation isolates OT systems from IT networks, limiting the spread of ransomware. Shieldworkz designs tailored segmentation strategies to protect critical assets.

• Why It Matters: The VARTA Group attack could have been contained with better segmentation, preventing plant-wide shutdowns.

• Shieldworkz Solution: We implement micro-segmentation and zero-trust policies to ensure attackers can’t move laterally across your network.

3. AI-Driven Threat Detection

Ransomware evolves quickly, but so do we. Shieldworkz uses AI-powered monitoring to detect anomalies and threats in real time, from suspicious USB activity to unusual network traffic.

• Why It Matters: AI-driven detection reduces breach costs by 35% through early intervention.

• Shieldworkz Solution: Our platform learns your OT environment’s normal behavior, flagging deviations before they escalate.

4. Secure Remote Access

Remote access is a common entry point for ransomware. Shieldworkz enforces secure, role-based access controls for vendors and employees.

• Why It Matters: Brute-force attacks on VPNs targeted North American critical infrastructure in 2024.

• Shieldworkz Solution: We deploy multi-factor authentication (MFA) and encrypted remote access tools to lock out unauthorized users.

5. Incident Response and Recovery

When ransomware strikes, every minute counts. Shieldworkz provides OT-specific incident response playbooks and immutable backups to minimize downtime.

• Why It Matters: Regular backup testing reduces ransomware impact by 50%.

• Shieldworkz Solution: Our team guides you through rapid recovery, ensuring critical systems are back online with minimal disruption.

5 Actionable Steps to Defend Your OT Systems in 2025

Ready to protect your manufacturing plant from ransomware? Follow these practical steps to strengthen your industrial cybersecurity:

Step 1: Conduct a Risk Assessment

Identify your most critical OT assets and vulnerabilities. Use tools like Shieldworkz’s asset discovery to map your network and prioritize risks based on business impact.

• Action: Perform a gap analysis to uncover unpatched devices, open ports, or weak credentials.

• Shieldworkz Tip: Our risk assessment framework aligns with IEC 62443 standards, ensuring compliance and security.

Step 2: Implement Network Segmentation

Isolate OT systems from IT networks to contain potential breaches. Use firewalls and DMZs to create secure zones for critical assets.

• Action: Deploy micro-segmentation to limit lateral movement. Test segmentation regularly to ensure it holds.

• Shieldworkz Tip: We design OT-specific segmentation strategies that minimize downtime during implementation.

Step 3: Enhance Employee Training

Your team is your first line of defense. Train OT engineers and plant staff to recognize phishing attempts and follow secure USB protocols.

• Action: Conduct quarterly cybersecurity awareness sessions tailored to manufacturing environments.

• Shieldworkz Tip: Our training modules bridge IT and OT cultures, empowering your team to spot threats early.

Step 4: Deploy Real-Time Monitoring

Use AI-driven tools to monitor OT networks for anomalies, such as unusual traffic or unauthorized access attempts.

• Action: Implement SIEM or SOAR tools to centralize threat detection and response.

• Shieldworkz Tip: Our platform integrates with existing OT systems, providing real-time alerts without disrupting operations.

Step 5: Test Incident Response Plans

Simulate ransomware attacks to test your response and recovery processes. Ensure backups are offline and immutable to prevent encryption.

• Action: Run tabletop exercises annually to refine your OT incident response playbook.

• Shieldworkz Tip: We provide customized playbooks and simulation tools to prepare your team for real-world scenarios.

Emerging Threats to Watch in 2025

Ransomware isn’t the only threat to your OT systems. Stay ahead of these emerging risks:

• AI-Powered Attacks: Cybercriminals are using AI to automate phishing and scale ransomware campaigns.

• Hacktivist Campaigns: Groups like Hunt3r Kill3rs target OT systems for political motives, disrupting operations with wiper malware.

• Supply Chain Vulnerabilities: Third-party vendors remain a weak link, as seen in the Crowdstrike incident.

• IIoT Exploits: The growing number of IIoT devices (projected to reach 50 billion by 2030) expands the attack surface.

Shieldworkz stays ahead of these threats with proactive threat intelligence and tailored OT security solutions, ensuring your plant is ready for 2025’s challenges.

Conclusion & Call to Action

Ransomware is a growing threat to manufacturing, but with the right industrial cybersecurity strategy, you can protect your OT systems and keep production running. By prioritizing asset visibility, network segmentation, AI-driven detection, secure remote access, and robust incident response, you can defend your cyber-physical systems from even the most sophisticated attacks. Shieldworkz is here to guide you every step of the way, with solutions tailored to the unique needs of manufacturing environments.

Don’t wait for a ransomware attack to disrupt your operations. Download our free OT & IOT Threat Landscape Report, “Securing OT Systems: A 2025 Roadmap for Manufacturers,” to dive deeper into these strategies. Or request a demo with Shieldworkz to see how our platform can safeguard your plant today. Visit shieldworkz.com to get started.