Critical Manufacturing Legacy Systems



     One common item that information Security Professionals working in Critical Manufacturing environments have to deal with is that of legacy systems. You see, in Critical Manufacturing environments it is very common for the systems that run and control factory lines to remain in place for a very long time. Some of these systems can be running Operating Systems(OS) that are 10 to 15 years out of date. In many cases these OS are no longer vendor supported and cannot be patched to remediate known exploitable vulnerabilities. These older systems are often used to run production lines and they still do a great job at doing what they were purchased to do.  It is difficult, rightly so, to convince the leadership team at a factory to spend money to replace something that is old but that is still doing the job it was purchased to do. It cost money and reduces potential profits to replace these old and outdated systems with new systems.  Because they continue to do the job they were purchased to do justifying the new spend can be a difficult thing to do.   

     From an Information Security point of view these systems pose a large risk to the overall manufacturing environment and if hacked could cause a large scale production outage.  In smaller companies this type of major Cyber attack can result in no longer being able to conduct business and permanently closing the doors.   Legacy systems that are commonly found on the shop floor are often 3, 4 or even 10 years out-of-date when it comes to standard Information Technology patching.  Information Security Professionals look at these systems as attack vectors while the people working in the Critical Manufacturing environment view them as cost effective work horses that are getting the job done. While cyber attacks on networks at Sony, Target, Home Depot and the US Government are getting all the press, the greatest cyber vulnerability is in manufacturing. “By raw numbers, and by the numerous manners of attacks, manufacturing is the most targeted area now, even compared to financial services,” Chet Namboodri, senior director of Global Private Sector Industries at Cisco, told Design News. “Financial services gets more press, but industrial networks get more attacks.” Attacks and warnings such as Stuxnet, Armaco, SolarWorld and U.S., Steel to U.S. regulators and security experts sending out an official warning that hackers could now access critical medical equipment including pacemakers and insulin pumps with potentially deadly results make the threat to Critical Manufacturing a real one.  Determining what to do in order to lock down and protect the Legacy systems while at the same time allowing them to continue doing the work they have been doing is a  major part of an Information Security professionals job.

     “You can’t scan that system (or you can’t put AV on that system) because it is old and fragile and if you bring it down we will not be able to produce our product”  Is way too common of a phrase in the Critical Manufacturing environment. In many cases Information Security Professionals are asked/told to please just leave the systems alone, do not run vulnerability scans, do not put antivirus on them, do not put a light firewall on them, do not patch them, do not put updates on them, etc.  This type of thinking by Information Technology and Factory leadership teams is shortsighted and is putting their entire production capability at huge risk of catastrophic failure.  As these legacy systems are outdated and no longer being supported by the vendor they are hugely exploitable to any blackhat or hacker that wants to take advantage of their exploitability. The reality is that the risk is real,  the risk is great and from past events we know that these systems pose easy to use attack vectors for blackhats, fraudsters and competitors seeking to cause negative business impact to the company.  

     Information Security professionals working in Critical Manufacturing should take the approach shown in Table 1 for dealing with the Computer Systems residing in the factory environment and that are on the plant floor.  By following this methodology the legacy systems will be protected while at the same time be able to continue doing the job they are good at and that they were purchased to do.  In most cases this approach will also reduce the overall risk that these systems pose to an acceptable level.

Legacy TableTable 1

This approach when combined with the network segmentation and smart firewall approach discussed in my previous blog on Critical Manufacturing is the start of a successful recipe in securing a Critical Manufacturing environment.

About mclaukl

Professional Certifications - Certified CISO, CISM, CISSP, PMP, ITIL Master Certified, GIAC Security Leadership Certificate (GSLC), CRISC. Kevin also holds Certificates in the Advanced Principles of Information Security and in Advanced Information Security Research Methods from Jones International University. Kevin L. McLaughlin began his career as a Special Agent for the Department of Army. He was responsible for investigating Felony crimes around the globe. He has had many careers over the years, including being a Police Officer in Kissimmee Florida, an Investigator for Mastercard/Visa, a Middle School teacher, a Director at Kennedy Space Center (where he worked with Fred Hayes, James Lovell, Armstrong, Sheppard, etc.), the President of his own company, an IT Manager and Senior Information Security manager with the Procter & Gamble (P&G) company (fortune 35), a CISO at the University of Cincinnati and a Senior Information System Security Manager for the Whirlpool Corporation (fortune 125). Kevin has also been an adjunct since 1992. While at P&G Kevin created one of P&G’s augmentation outsourcing teams in India. Kevin designed and implemented this India team and it won a global Gold Service award from Atos-Origin and has acted as a model for countless corporate relationships since. Over the years Kevin has: created an Information Security program conducted Information Security Strategic planning designed Information Security solutions, investigated over 700 Cyber cases and operated a Global Security Operations Center. • Education - MS in Computer Science Education, BS in Management of Information Systems * PhD in Cyber Security, University of Fairfax
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