1. Skills Gaps

Cybersecurity workforce issues have become common discussion topics, especially as professionals in this industry face increasing challenges securing legacy systems against emerging technologies. For example, some scammers use artificial intelligence chatbots to craft phishing messages, making the content more realistic and broadening its reach.

Numerous initiatives have focused on recruiting more people into cybersecurity roles, and such efforts should help. However, securing legacy systems requires specialized expertise to facilitate protecting outdated networks while ensuring continued functionality and connectivity.

A 2026 global study revealed that 60% of organizations lack the necessary skills within their cybersecurity teams. That figure contrasts with the 40% dealing with staffing shortages. The findings highlight the need for decision-makers preparing for legacy system security upgrades to ensure staff members have relevant experience. They must understand the challenges of protecting these older systems against emerging threats.

2. Options for Improving Preparedness

Securing legacy systems in manufacturing settings or other environments involves understanding the most likely attack types and how cybercriminals may orchestrate them. IT departments can get some of that information through detailed audits that reveal how well the organization follows cybersecurity best practices and which areas need urgent improvement.

A 2025 study found that only 30% of manufacturers felt prepared to defend against deepfake attacks. The figure was only 37% when asked about their readiness to defend against distributed denial-of-service incidents.

As IT team members evaluate the best ways to secure legacy infrastructure in manufacturing plants, they should remain perpetually aware of existing or emerging vulnerabilities that could increase the risk of these attacks and others. It is especially important to do so if the people overseeing these projects feel tempted to address weaknesses later. Delays could give cybercriminals entry points, making other security upgrades less effective.

3. Operational Technology

Information technology traditionally focuses on protecting data. Although that is a critical concern when safeguarding legacy systems, the involved parties must also adequately consider operational technology. Some of those systems run for 15 to 30 years or longer. As usage time frames lengthen, OT infrastructure becomes less compatible with modern security measures.

Parties supervising the upgrades should begin by cataloging all known vulnerabilities and developing appropriate defensive measures. If analyses indicate the systems are too old to be secured, decision-makers should strongly consider phasing them out when resources allow.

Upgrades should also cover connectivity options for operational technology infrastructure and how they could enlarge the overall attack surface. For example, third-party vendors may receive remote connectivity privileges. This makes it more difficult for people within manufacturing companies to verify activities and ensure that external entities comply with all necessary cybersecurity measures.

4. Access Control

Securing legacy manufacturing systems requires understanding existing access control measures and whether they remain sufficient against new threats. Relevant evaluations should also examine how diligently a company's administrators have granted and revoked access during workforce changes. Shortcomings could mean that people who have not worked at a factory for years can still access its most critical data.

Some organizations have inappropriate access control because such measures did not exist when they began using the relevant legacy systems. One expert recalled encountering an older network used for medical records where 75% of clinical workers had administrative privileges for the contents. A deeper investigation into the matter revealed that this occurred because the client had begun using the original system while expanding its emergency room in the 1990s, and granular controls did not exist then.

The person dealing with this matter created a hybrid system so legacy credentials remained valid, but the implementation of new authentication measures modernized access control and strengthened security. That workaround illustrates why manufacturing companies and similar places do not necessarily need to scrap older information, especially if involved parties think creatively to address workforce needs and gradually enact changes.

5. Worker Errors

Manufacturing plants are busy places, and many people must juggle numerous tasks simultaneously. Such arrangements could make them less likely to follow cybersecurity best practices, especially if they have never received thorough training. One 2023 study found negligence or carelessness accounted for 98% of security breaches that year.

Even if employees understand their collective role in preventing cyberattacks, preventive measures may not come naturally to them. That is particularly true if they have used legacy systems for years, and IT professionals have only recently instituted new security protocols.

Executives should remember that it takes time for people to change and adapt to new conditions, so compliance may not occur immediately. However, they should get better results by putting themselves in the position of reluctant workers and explaining how times have changed, so tighter security measures have become essential.

Keeping Manufacturing’s Legacy Systems Safe

Protecting legacy systems in manufacturing plants is not easy, especially with cyberattacks becoming more diverse, frequent and severe. However, IT teams must consider older infrastructure in their cybersecurity plans, especially because vulnerabilities may give motivated cybercriminals easy access. Proactiveness is among the best measures to prevent and defend against potential incidents.