Manufacturing technology does not always get replaced just because something newer comes along. However, the problem with that is older technology can create security and reliability risks. CISA notes that industrial control systems can remain in operation for decades, sometimes leaving manufacturers with unsupported devices or deferred security updates.
Supporting legacy systems in manufacturing requires finding a balance between keeping production moving and reducing the risks that come with aging technology.
Take Inventory of Legacy Software and Hardware in Your Manufacturing Business
The first step is knowing exactly what is still running. Manufacturers should maintain an inventory of older computers, servers, operating systems, software, industrial control systems, and network-connected equipment.
Once those systems are documented, your IT team can determine:
- Whether the manufacturer still supports them
- Whether security patches are available
- What other systems they connect to
- How important they are to production
- What would happen if they stopped working
A system that has been quietly running in the corner for 15 years can still become a major problem if nobody knows what depends on it.
Separate Legacy Manufacturing Systems From The Main Network
Older systems may not support modern security features, but that does not mean they need unrestricted access to everything else.
Network segmentation can separate legacy manufacturing equipment from business systems such as email, accounting, and general office computers.
CISA recommends placing control system networks behind firewalls and isolating them from business networks when possible.
Control Remote Access to Older Equipment
Remote access can make manufacturing support easier, especially when vendors need to troubleshoot specialized equipment. It can also create another way into your network if it is not properly secured.
Avoid exposing legacy equipment directly to the internet. Where remote access is necessary, manufacturers can use protected access points, monitoring, and multi-factor authentication where supported. CISA specifically recommends reducing internet exposure and using MFA and monitored access for systems that must remain accessible.
Keep Legacy Systems Updated When Possible
A legacy system does not necessarily mean an unmaintained system. Continue installing vendor-supported security patches and firmware updates when they are available and have been tested for compatibility with production equipment.
Manufacturing environments require extra care because an update that works perfectly on a standard office computer could affect specialized software or machinery. Updates should be planned and tested instead of applied blindly during production.
Back Up Critical Manufacturing Systems
If an older system fails, replacing the hardware may be only part of the problem.
Configuration files, specialized software, production settings, and other information may also be difficult to recreate. Maintain secure backups of critical data and system configurations, and make sure those backups can actually be restored. A good recovery plan can turn a major production interruption into a much more manageable problem.
Plan for Legacy System Replacement Before It Becomes an Emergency
Some legacy systems can be safely supported for years. Others eventually become too risky or unreliable to keep.
Rather than replacing everything overnight, manufacturers should keep an eye on which systems create the most risk and build a realistic modernization plan around production schedules, budgets, and operational needs.
tech42 provides managed IT services for manufacturing and industrial businesses designed to improve system reliability, security, and efficiency.
If aging technology is becoming harder to maintain, tech42 can help evaluate your current environment and create a plan that keeps production moving while reducing unnecessary IT risk.
Contact us today.
