Industrial cybersecurity Crisis-proof manufacturing: Fail-to-wire protects industrial production

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Palo Alto Networks (Germany) GmbH

FAULHABER Drive Systems

Ever more complex cyberattacks threaten production. With fail-to-wire, operations continue even if the firewall fails. Embedded in an AI-powered security platform, the concept offers increased security in Industry 4.0 at low costs.

In today's connected industrial world, numerous companies face a critical challenge: How can they maintain production if the firewall fails? This question is becoming increasingly crucial because, in manufacturing, security and plant availability are inseparably linked. A failure can halt production and cause millions in losses. Ever more sophisticated cyberattacks based on AI and ML exploit the interconnection of IT and OT. The Fail-to-Wire concept, based on a unified security platform with Zero Trust, promises to keep production running even in times of crisis. But how does it work?

Growing threat from cyberattacks

The threat landscape for industrial processes has changed in recent years. Cybercriminals are increasingly focusing on the OT area—the heart of operational business processes. Particularly alarming is the fact that many of these attacks originate in the IT infrastructure and then spread to the OT systems. The consequences of such attacks are often devastating: from production outages and massive revenue losses to long-term financial damage.

Given this development, it is not surprising that cybersecurity has become a top priority for industrial companies. Nevertheless, many firms face significant challenges in implementing effective protective measures—from IT to the shop floor. Companies must bridge the gap between their IT and OT departments to effectively address security risks.

Weakness of industrial cybersecurity

The close connection between IT and OT offers cybercriminals new attack opportunities and poses challenges for many companies. The reasons often lie in the different tasks and goals: IT departments take care of data and networks, while OT teams control and monitor production processes. These differences also influence cybersecurity decisions: Only in 40 percent of cases do IT and OT share responsibility for security investments, according to the "State of OT Security" report by ABI Research and Palo Alto Networks. In 28 percent of companies, OT has a say, but IT ultimately decides. Only twelve percent of respondents said that both teams agree on such decisions.

Another problem: IT and OT often require different security solutions. This necessitates reliable processes that accommodate the varied experiences of employees. Particularly important is the firewall between IT and OT as a digital safeguard. If it fails, the consequences can be severe. In the worst case, the entire production comes to a halt, which can quickly result in million-dollar losses. Reliable solutions are needed to minimize risks and make companies more resilient. Especially the shop floor needs good protection that does not jeopardize plant availability.

Continuity despite crisis

In response to these challenges, Fail-to-Wire is increasingly being adopted in certain areas. Unlike conventional firewall systems, whose failure would result in a complete production stoppage, Fail-to-Wire keeps operations running—even if the firewall fails. The system uses a loop in the network for this. If the firewall fails, data traffic is routed through a physical detour. This way, the connection between different systems remains intact. However, it should be noted that in this state, data flows without the usual security checks. Companies should be aware of this compromise between continuous operation and security.

To mitigate potential dangers during this time, segmentation into security zones plays a crucial role. Each production line is divided into its own security zone, allowing targeted isolation and control of data traffic. This structure prevents lateral movements within the network, even if an attacker manages to penetrate one zone. If a hacker gets into the first security zone, they cannot simply access the second or third zone with the information obtained. These additional hurdles make it more difficult for attackers to take over the system and significantly enhance the security of the entire system. Thus, production remains secure despite any compromise.

Layered firewalls as a bulwark

By layering different firewalls for production lines, additional hurdles can be integrated. To access critical systems, an attacker must first get through several security measures. Typically, these include the perimeter firewall protecting the corporate network and specific firewalls between IT and OT. This multi-layered defense strategy not only enhances security but also gives companies more time to detect and respond to potential threats. The strategy is even more effective with modern technologies, such as a unified platform solution from Palo Alto Networks with Precision AI and based on Zero Trust. The system enables real-time monitoring of control commands and quick detection of suspicious activities.

Precision AI is a proprietary AI system that combines accurate predictions and automated defense measures with the user-friendliness of generative AI—an enormous advantage for responsiveness. The technology builds on proven AI/ML approaches but is specifically adapted for cybersecurity. Precision AI collects data at a central point and analyzes it with specialized models, supporting security teams in protecting the infrastructure. The system uses both old and current data to respond in a timely manner to previously unknown threats. It learns from a vast amount of security data, automating the detection, prevention, and response to risks. This enables intruders to be quickly identified and isolated.

Protection on all levels

Fail-to-Wire and unified security platforms based on Zero Trust offer many opportunities to comprehensively protect industrial plants. This is especially true for Industrial Control Systems (ICS) and Scada environments (Supervisory Control and Data Acquisition) that are used to monitor and control technical processes. The approach utilizes AI and ML protection to safeguard ICS and Scada environments from threats that may originate from corporate systems.

The segmentation of the environment and the Zero Trust strategy complement the platform approach. This results in different areas of the network being separated. The so-called Purdue Levels and IEC 62443 standards are recommended here, focusing on the company's key assets while considering both security and regulatory requirements. A reliable verification of user identity and granular rights allocation prove effective for secure and authorized access to critical control systems. Additionally, remote access management plays an important role, especially in times of increasing digitalization and flexible work models.

Resilience through holistic security concepts

In practice, Fail-to-Wire proves itself on the shop floor and particularly in cell manufacturing. With this concept, production can continue even if security elements fail. This prevents costly downtimes, reduces delays, and helps maintain safety. Implementing Fail-to-Wire requires good planning and smart integration into the existing network. A unified security platform plays a crucial role in this process, supporting Fail-to-Wire by providing a comprehensive overview of the entire network and enabling quick responses to security incidents.

It is important to firmly integrate Fail-to-Wire into a comprehensive corporate security strategy. This makes companies more resilient, as they can continue working in critical situations and are well protected. In today's world, where cyber threats are increasing, companies with such advanced concepts have a clear advantage. They can not only better contain attacks but also respond to them more quickly. Ultimately, it is about finding a balance between business continuity and cybersecurity—a challenge that modern industrial companies must face to remain competitive in the digitalized world. Fail-to-Wire proves to be a reliable platform solution from Palo Alto Networks for ICS and Scada environments.

*Dharminder Debisarun is Smart Industries Cybersecurity Executive at Palo Alto Networks.