Your production output depends on systems that cannot afford sudden disruptions. Yet one of the most avoidable cybersecurity risks in manufacturing is simple: known vulnerabilities left unpatched. Attacks exploiting vulnerabilities with published fixes surged 54% year over year.
For manufacturers, this surge often results in unplanned downtime, stalled throughput, and increased exposure to cyber threats, including ransomware and data breaches, across both IT and Operational Technology (OT) environments. Even small gaps weaken your security posture and jeopardize production KPIs such as cycle time, order fulfillment, and on-time delivery across plants.
Effective patch management in manufacturing closes these openings early, strengthens cybersecurity, and protects critical systems before they trigger expensive line stoppages or missed production targets.
This article explores how a consistent patching program demonstrates a straightforward, well-documented process to auditors.
Key takeaways
- Unpatched OT assets increase downtime risk and disrupt throughput across PLCs, HMIs, and plant-floor systems.
- MSP-led patching lowers MTTP and stabilizes uptime by eliminating backlog and reducing human error.
- Automated patch management improves production reliability by preventing firmware drift and ensuring consistent updates across mixed-vendor environments.
What is patch management, and why does it matter in manufacturing
Patch management provides a structured approach to applying software updates, removing known vulnerabilities, and maintaining production stability. Manufacturing operations rely on tightly integrated systems across IT and OT. Many assets run on older operating systems that can break down or become vulnerable to exploitation without regular maintenance.
A defined patch management process protects throughput, reduces unexpected stoppages, and supports KPIs such as cycle time and on-time delivery.
Understanding the patch management process
An effective patch management process starts with complete visibility into every IT and OT asset. You maintain an accurate asset inventory, track available patches, and monitor vendors for changes that affect servers, endpoints, PLC firmware, and human–machine interface (HMI) software.
Before updating, you test security patches and bug fixes in a controlled environment to ensure functionality.
A predictable sequence keeps production stable:
- Identify assets and confirm versions
- Track new software updates and vendor advisories
- Test patches to validate stability
- Deploy during scheduled windows
- Verify performance and document remediation
This structure reduces failed deployments and helps teams control risk.
Identifying vulnerabilities in manufacturing environments
Manufacturing plants operate equipment with long lifecycles. Legacy controllers, outdated HMIs, and unsupported Windows builds often cannot self-update, creating persistent exposure. These weaknesses span the production environment, especially when unsupported devices interact with modern systems.
You improve safety and uptime by mapping your OT environments and Industrial Control Systems (ICS) assets, and following ICS security guidance to ensure vulnerable devices are properly segmented. This mapping informs update scheduling and highlights where you need segmentation or compensating controls.
Real-world risks of skipped patches
Skipped patches create predictable and well-documented attack paths that threat actors routinely exploit.
WannaCry in 2017 shut down factories around the world by targeting unpatched Windows systems and proved how a single missed update can stop production at scale.
Ransomware groups in 2025 are increasingly exploiting known and unpatched vulnerabilities to move laterally across flat networks, highlighting the importance of building cyber resilience in manufacturing.
Even a single unpatched device can expose controllers, HMIs, and connected plant-floor systems to attack.
Prioritizing vulnerabilities by criticality, segmenting at-risk assets, and enforcing consistent patch cycles lowers the chance that an overlooked device disrupts production or triggers costly recovery work.
The hidden cost of unpatched systems: downtime and disruption
Unpatched systems commonly cause production outages that slow throughput, interrupt ERP and MES workflows, and undermine efforts to prevent production downtime. They also push operators to take extra manual steps, which increases unit costs.
Unplanned downtime in manufacturing can cost up to $260,000 per hour, and downtime now costs 50% more than in 2019 or 2020.
Consistent patching delivers clear ROI by preventing costly downtime.
How vulnerabilities create downtime events
Unpatched vulnerabilities often result in system isolation. When a workstation or controller becomes compromised, it must be taken offline immediately, stopping the line. Failed patch deployments or incompatible operating systems also trigger restarts and rollback cycles.
Direct cause→effect examples to highlight for executives:
- Unpatched controller → isolation → halted line → labor idle time.
- Incomplete update → MES disconnect → slowed batch processing → reduced throughput.
- Compatibility failure → rollback → delayed shift changeover → lower output per hour.
IBM reports that automotive manufacturers lose about $22,000 for every minute of downtime.
Financial and operational impact
Beyond the direct financial hit, downtime causes productivity losses and unfulfilled orders that ripple through the supply chain, and strengthening manufacturing supply chains depends on keeping systems up to date and stable. Missed shipments, delayed production runs, and stalled workflows cause cascading effects for suppliers, distributors, and customers.
Downtime affects every primary production KPI. When systems fail:
- Cycle time increases
- Throughput drops
- On-time delivery suffers
- Scrap and rework levels rise
- Labor efficiency falls
- Energy cost per unit increases
Linking patching activity to these metrics helps executive teams see how update discipline protects margin, prevents schedule disruptions, and reduces supply chain exposure.
Compliance consequences
Compliance frameworks evaluate patching because outdated systems contribute to preventable security events. Missing updates can weaken alignment with CMMC, ISO 27001, NIST 800-171, and operational controls such as NERC CIP. These gaps often show up as control issues during audits, and failed audits can directly lead to lost contracts and reputational damage.
A consistent patching program demonstrates a transparent, well-documented process to auditors, especially for manufacturers preparing for CMMC compliance.
Patch management in manufacturing environments: unique challenges
Manufacturing environments face constraints that corporate IT typically does not. Aging equipment, mixed vendor stacks, and distributed plants complicate timely patching. 65% of manufacturing companies had at least one actively exploited vulnerability in their IT or OT systems.
A risk-based strategy helps address these security gaps without affecting production commitments.
Managing legacy OT equipment and unsupported firmware
Older OT equipment often runs outdated firmware and cannot accept current patches. ICS devices in this category are known to hold vulnerabilities that attackers continuously test. You reduce exposure by isolating legacy equipment, applying segmentation, validating updates in controlled environments, and planning remediation in scheduled windows.
Coordinating mixed vendor ecosystems
PLCs, HMIs, and SCADA systems from different vendors follow different patch cycles, and smooth manufacturing system integration becomes harder when firmware is outdated or inconsistent. Some updates require prerequisite firmware or alter communication protocols. Reviewing vendor notes, confirming compatibility, and testing updates before rollout prevent unnecessary disruption.
Unified patch management tools and clear update workflows support consistent execution across sites. A risk-based order of operations ensures the most critical systems are updated first.
Scheduling updates in limited maintenance windows
Manufacturing rarely offers extended patch windows, so updates must align tightly with planned outages and preventive maintenance cycles.
You evaluate downtime risk, coordinate approvals, and stage a seamless rollout to minimize disruptions and maintain system functionality.
Maintaining visibility across distributed plants
Different plants update at various times, creating inconsistent patch status and blind spots.
A real-time dashboard, supported by accurate asset inventory data, helps teams quickly identify exposure. Vulnerability scanning and threat intelligence provide early warning signals and guide scheduling decisions.
How managed IT streamlines patch management for manufacturers
Managed IT simplifies patching by centralizing workflows, reducing manual effort, and improving accuracy across IT and OT environments. Instead of each plant maintaining a separate approach, you gain a unified method that lowers Mean Time to Patch (MTTP), reduces labor hours, and supports more predictable update cycles.
Automating patch deployment
Managed IT teams use centralized dashboards and patch management software to coordinate automated patch management across servers, endpoints, and OT assets. Automating patch deployment reduces technician workload, limits errors, and ensures updates follow a consistent schedule. Providers also track remediation steps to confirm issues are resolved.
A structured rollout process reduces rework and prevents unexpected interruptions during production.
Automation creates clear advantages:
- Lower MTTP across all sites
- Reduced manual labor
- Fewer failed deployments
- Consistent update windows
Monitoring patch status in real time
You gain real-time visibility into missing patches, failed updates, and systems that need attention. Managed IT teams utilize continuous vulnerability scanning and threat intelligence to identify exposure early, enabling security teams to respond quickly.
This proactive approach shortens Mean Time to Patch (MTTP) and limits the risk of unresolved vulnerabilities impacting production.
Validating patch safety with vendors
Before patches reach production, managed IT teams coordinate with equipment providers to test software updates in a controlled test environment. They test patches on Programmable Logic Controllers (PLCs) and related programs to confirm compatibility and stability.
This validation prevents communication errors, workflow disruptions, or controller issues during production.
Clear sequence:
- Tested patch → verified stability
- Verified stability → safe deployment
- Safe deployment → uninterrupted production
Aligning patching with compliance frameworks
Managed IT aligns patching with compliance requirements, including NIST, CMMC, and ISO. Teams generate audit-ready reports based on your patch management policy and support a documented patch management strategy.
This enhances your security posture and supports broader risk management objectives.
Key Metrics to Track in Patch Management Programs
These metrics create accountability, enhance planning, and enable teams to target updates that protect business performance.
| Metric | Why It Matters |
| Patch Compliance Rate | Indicates coverage across devices |
| Mean Time to Patch (MTTP) | Measures responsiveness to new vulnerabilities |
| Patch Failure Rate | Tracks success of updated deployment |
| Number of Critical Vulnerabilities Outstanding | Reveals exposure to known exploits |
| Average Downtime from Patching | Reflects efficiency of updated process |
How Keystone simplifies patch management for manufacturers
Keystone reduces patching overhead by coordinating updates across IT and OT systems, validating changes with vendors, and providing real-time visibility into exposure. This lowers MTTP, reduces labor hours, and protects production availability.
Keystone delivers:
- Automated patch management for servers, endpoints, PLCs, and HMIs
- OT-safe patch deployment workflows that include compatibility testing with PLC and HMI providers
- Scheduling that streamlines updates across all IT and OT assets while minimizing plant downtime
- Direct validation with equipment providers to prevent logic or communication conflicts
- Complete remediation tracking tied to individual assets
- Real-time dashboards showing missing patches, failures, and environmental exposure
- Protection for critical systems that cannot tolerate extended maintenance cycles
- Support for deploying patches that close active security vulnerabilities
This approach lowers operational workload, reduces the risk of update failures, and helps teams maintain predictable plant operations across all sites.
Final thoughts: patching as preventive maintenance for your digital factory
Strong patch management in manufacturing protects production, lowers the total cost of ownership (TCO), and reduces avoidable outages that slow teams down. When you follow proven patch management best practices, you limit downtime, prevent cyber threats from reaching vulnerable assets, and keep critical systems stable across every shift.
Talk to Keystone about automating patch management for your manufacturing environment.
FAQs
What does patch management in manufacturing actually involve?
Patch management in manufacturing involves identifying outdated systems, testing updates in a controlled environment, and deploying patches on a defined schedule.
How often should manufacturers apply patches to OT systems?
Manufacturers should patch OT systems when vendors release stable updates that have been validated for compatibility in a test environment. Changes must be timed with maintenance windows to avoid production impact.
How does patch management help prevent downtime in manufacturing?
Patch management prevents downtime by addressing known issues before they cause failures or security incidents. Updates eliminate logic faults, communication drops, and vulnerabilities that can halt production lines. Aligning patching with maintenance windows keeps output stable and reduces the cost of emergency repairs.
