AI at the forefront as manufacturers confront rising cyber security risks

Manufacturers worldwide are placing cyber security at the top of their strategic agendas as industrial operations face a rising tide of cyber attacks.

Key takeaways:

• AI is becoming central to manufacturing cyber security — 61% of cyber security professionals plan to adopt AI and ML tools within 12 months, outpacing other industries.
• Cyber security is now a board-level issue — With IT and OT increasingly converging, cyber risk has become one of the top external threats to manufacturing growth, second only to economic pressures.
• Skills shortage remains a critical barrier — While technology adoption accelerates, manufacturers face ongoing challenges in recruiting and training workers with the cyber security expertise needed to protect operations.

According to Rockwell Automation’s 10th annual State of Smart Manufacturing Report, cyber risk is now ranked among the most serious external threats to growth, second only to economic pressures such as inflation.

For the first time, cyber security is firmly positioned as a board-level concern. The report, based on insights from more than 1,500 manufacturing leaders across 17 major markets, reveals that one in three respondents hold direct responsibilities for both information technology (IT) and operational technology (OT) security — underscoring the deepening convergence between digital and physical infrastructure.

AI adoption accelerates in security strategies

As factories modernize, the fusion of IT and OT has significantly widened the attack surface. To respond, 61% of security professionals in manufacturing plan to adopt artificial intelligence (AI) and machine learning (ML) tools within the next 12 months. This adoption rate is outpacing broader industry AI uptake by 12 percentage points, highlighting how critical automation has become in combating cyber risks.

AI-enabled detection and response tools are increasingly viewed as essential for keeping production lines safe from disruption. With manufacturers facing sophisticated threats targeting industrial control systems, real-time monitoring and predictive capabilities are now central to maintaining uptime and ensuring resilience.

Cyber security drives smart manufacturing investments

Interestingly, cyber security has emerged as the leading use case for smart manufacturing data. Rockwell’s research shows that 38% of manufacturers intend to apply insights gathered from connected devices directly to strengthen protection measures. Furthermore, nearly half (48%) of cyber security professionals identified securing converging IT/OT architectures as a top strategic priority over the next five years.

This shift positions cyber security not just as a defensive measure, but as an enabler of innovation. Secure digital foundations are increasingly seen as prerequisites for adopting advanced technologies, from AI-driven analytics to autonomous production systems.

Workforce challenges add pressure

Despite technological progress, workforce development continues to lag behind. The survey points to ongoing shortages of skilled cyber security talent, alongside training challenges and rising labor costs. Large enterprises, in particular, are emphasizing the need for advanced cyber skill sets: 53% of respondents from companies exceeding $30 billion in revenue identified cyber security standards as critical hiring priorities.

This talent gap reinforces the necessity of pairing technical investment with workforce capability. As manufacturers recruit the next generation of digital operators, cyber fluency and analytical skills are fast becoming as important as mechanical expertise.

Cyber security as a growth enabler

Stephen Ford, Rockwell’s Chief Information Security Officer, noted that cyber security is now integral to competitiveness: “It’s no longer just about preventing threats, it’s about empowering transformation with confidence.” Manufacturers that integrate AI-driven cyber strategies are better positioned not only to defend against attacks but also to accelerate digital transformation initiatives.

The findings highlight a broader truth for the sector: in the era of Industry 4.0, protecting operations and enabling growth are inseparable goals. For manufacturing leaders, investment in AI-powered cyber security is no longer optional — it is a core component of sustainable industrial success.