Manufacturing is experiencing two major shifts — a wave of retirements and a rapid move toward digital transformation. Together, these changes can create cybersecurity gaps when left unaddressed. Understanding and preparing for the risks is key to maintaining secure and stable operations.
The Inevitable Wave: A Generational Shift in Manufacturing
The “silver tsunami” refers to the large-scale retirement of the Baby Boomer workforce, which can be especially impactful in the manufacturing sector. According to research by Lightcast, 80% of the 5 million workers who left the labor force from 2020 to 2024 were 55 years or older.
Many of these workers have decades of experience with specialized equipment and complex production environments. They have amassed a rich trove of knowledge, including unwritten insights about how systems behave or how to operate older equipment safely. When these employees retire, that knowledge often leaves with them.
For this reason, manufacturers may struggle with a knowledge gap that can slow operations or increase operational and security risks. With fewer experienced workers on the floor, it can be more challenging to respond quickly to problems or manage legacy systems.
Why the Knowledge Drain Creates a Perfect Cybersecurity Storm
Losing experienced personnel can create cybersecurity risks that can grow when left unaddressed.
Loss of legacy system expertise
Many manufacturing environments rely on legacy operational technology (OT). These systems are often older than modern security technologies and lack features like encryption or strong access controls.
Experienced workers will fully understand how these systems work, how to use and maintain them, and how to ensure minimal downtime on a daily basis. When they leave, companies may hesitate to update or patch these systems, leaving potential vulnerabilities unaddressed.
Risks of rapid digitization
To address labor shortages, some manufacturers are investing in industrial automation via the Internet of Things (IoT) and smart tools. These technologies improve efficiency, but may introduce new risks.
In some cases, companies may deploy new systems quickly to meet operational needs without adequately addressing security risks during setup. This approach can lead to weaker security from poor network segmentation or weak configurations.
As more devices connect to the system, attackers will also have more entry points to exploit. Rapid digitization without proper safeguards can create security gaps.
Increased vulnerability to social engineering
While newer employees are more digitally savvy, they may not have the same level of experience with cybersecurity practices, especially in industrial settings with legacy systems. This gap can make them more vulnerable to social engineering attacks, where cybercriminals exploit trust, fear and urgency to gain unauthorized access.
Phishing emails or fake requests can be harder to detect without proper training. In manufacturing environments, a compromised account can affect entire production lines. It can be challenging to manage these risks without the awareness that experienced workers often bring.
Bridging the gap: How to secure operations for the next generation
Manufacturers need a clear plan to address the workforce gap and the security risks it entails.
Prioritize a security-focused knowledge transfer
Capturing essential knowledge before employees retire is crucial, covering aspects like operational procedures and security practices tied to key systems.
Here are some effective approaches:
- Mentorship programs pairing experienced workers with newer employees
- Clear documentation of system configurations and response procedures
- Recorded walk-throughs of maintenance and troubleshooting processes
Knowledge transfer helps organizations remain resilient, even when experts retire.
Invest in secure digital transformation
Companies are gradually embracing digital transformation and AI as force multipliers, allowing more accurate insights and revenue growth. These changes are necessary to keep up with the market, but security must be part of the process from the start.
To better support this shift, companies need strong cybersecurity frameworks. Key strategies include:
- Applying zero-trust principles
- Segmenting networks to protect critical assets
- Running regular security assessments
- Including security requirements when selecting vendors or software systems
Leverage automation as a defensive tool
Automation can also support security needs. According to IBM, 64% of companies are already using AI-powered automation for security purposes, and 29% are evaluating implementation.
Tools that monitor systems, detect threats and respond automatically can fill gaps in human expertise. These solutions can identify unusual activity and often respond faster than manual processes when set up correctly.
Building a resilient and future-proof manufacturing floor
The silver tsunami is already affecting manufacturing. As experienced workers retire, the loss of knowledge is affecting operations and cybersecurity. Companies that act early and strategically can reduce these risks and bridge potential knowledge and technology gaps.
