Walking the tightrope: How manufacturers can balance digital transformation and cybersecurity

Manufacturers are embracing Industry 4.0, but digital transformation brings new cybersecurity challenges. Learn how strategic access management helps organizations modernize their operations confidently so every second of critical work stays both frictionless and secure.

Manufacturers are accelerating modernization and adopting Industry 4.0 technologies to improve efficiency and innovation. But every new connected device and vendor integration introduces new security risks.

That tension was the focus of the recent Imprivata LinkedIn Live, “Walking the Tightrope: Balancing Digital Transformation and Cybersecurity in Manufacturing,” featuring Chip Hughes, Chief Product Officer, and Chaitanya Yinti, Vice President of Product Management at Imprivata. Together, they explored how manufacturers can achieve digital transformation without compromising security or productivity.

What is digital transformation?

Digital transformation is generally defined as the set of strategies an organization deploys to adopt and integrate digital technology (IoT, big data, cloud computing, AI, etc.) into all facets of its business operations to reduce manual processes and increase employee efficiency. It’s a fundamental shift driven by the desire to deliver more value to customers through operational efficiency and embracing new technology. At most organizations, this may require a change in attitude and culture. Moving away from traditional operating models can create friction. But by moving towards digital transformation initiatives in the right way, companies can empower their staff and their customers to deliver even more benefits (and faster) than before, positioning themselves as a more sustainable business.

Modernization meets escalating cyber risk

As factories become more connected, the attack surface expands. Hughes pointed to the stark reality that 57% of manufacturers have experienced a ransomware attack in the past 12 months. “It’s a pretty incredible number,” said Hughes. “That kind of thing can cause downtime issues… roughly $125,000 per hour you are out because of a ransomware attack.”*

He explained that manufacturers face a constant balancing act. “There’s this balance between our responsibility in terms of that enablement and making sure we solve for that stuff and the corporate responsibility to make sure you have these pieces that can be patched,” said Hughes.

Even a brief interruption can cost millions and halt production for days, underscoring why cybersecurity must evolve alongside modernization rather than lag behind it.

Strategic access management as the foundation for secure modernization

Yinti noted that secure modernization starts on the shop floor. “When you talk to any person on the manufacturing floor who is responsible for not just the IT systems, but the OT systems as well, their priority is not typically security ,” noted Yinti. “Their job primarily is to drive as much efficiency out of those machines and get as much product out the door as efficiently as possible.”

Security controls that add friction quickly meet resistance. “Identity, security… anything that can potentially slow down that process is something they take a serious look at and say, ‘Hey, do I really need this extra login, MFA, security or anything else? Is that going to improve my efficiency? Or is it a hindrance?’”

A strategic approach — using multifactor and passwordless authentication with intelligent session control — ensures the right people have the right access at the right time. Security becomes part of the workflow rather than an obstacle to it.

Overcoming legacy infrastructure and silo challenges

Legacy infrastructure adds complexity. Hughes noted that “50% of manufacturers are saying that the average age of their OT assets is over 15 years old,” which creates challenges for security and modernization.*

Coordinating IT and OT is key. “If we can bring OT and IT together, it should be more cost-efficient,” he said. “You don’t have multiple systems. It should be a better end-user experience.”

A unified access framework bridges legacy and modern environments, ensuring visibility and consistency across workstations, shared devices, and cloud applications, so transformation can move forward securely and efficiently.

Securing shared devices and third-party access

Manufacturing operations rely heavily on shared devices, shift work, and third-party contractors, all of which are potential risk vectors if not managed properly. “Many of these systems, because they’re legacy, are built with simple user passwords,” said Yinti. “And many times, what the factory floor does is, they’ll have one username and one password that everyone on the floor shares. From a regulatory point of view, that’s a bad thing, because then you can’t account for which particular person on the floor was involved in the entire process.”

He added, “Contractors are absolutely a critical part of any manufacturing plant’s work… and so, making sure that when they come in, that access is secured, is critical.”

Zero Trust and risk-based authentication models — reinforced with Identity Threat Detection and Response (ITDR) — help manufacturers enforce least-privilege principles and continuously monitor for abnormal access without slowing production.

Preparing for next-generation security

When disruptions occur, resilience matters. According to Hughes, “When such things happen, when there is a ransomware attack from outside, and you want to lock down your manufacturing facility from outside… and still be productive, you need solutions that can do that.”

Building flexibility across on-premises, cloud, and hybrid environments ensures continuity even if networks are compromised. Manufacturers that integrate ITDR, risk-based authentication, and strong identity governance can maintainuptime and security in parallel.

What is the path forward for digital transformation success?

“There are real solutions out there that can help solve this,” Hughes concluded. “The IT team, the OT team… need to work together to drive a unified experience and provide a very modern but seamless way to access both IT and OT resources.”

Modern manufacturing success depends on secure, seamless access. By adopting a cohesive access management strategy, organizations can accelerate transformation, improve compliance, and protect critical operations from disruption.

Simple and secure access management is the foundation for resilient modernization because every second of critical work must be both frictionless and secure.

Looking to learn more?

Download the IDC InfoBrief, sponsored by Imprivata, Manufacturing’s Digital Transformation Dilemma, to explore practical strategies for strengthening access controls and enabling secure digital transformation.

* Statistical source: IDC InfoBrief, sponsored by Imprivata, Manufacturing’s Digital Transformation Dilemma, (IDC #US53662525, July 2025