Why Secure Managed File Transfer Is Critical for Manufacturing in the Age of AI 

Outdated file transfer tools may keep operations running, but only on the surface. Beneath that are systemic weaknesses: poor visibility, weak authentication, no audit trails, and no advanced content inspection or multilayered threat prevention. These aren't just inefficiencies but open doors for attackers, audit failures, and stalled automation.

In many manufacturing environments, removable media like USB drives are still used to transfer files across air-gapped and segmented networks. This creates blind spots that make it difficult to detect malware, validate data integrity, or enforce access controls. As Jeremy Fong noted, “In the beginning, they were letting USB drives in… that’s the main problem.” Even seemingly ‘safe’ transfers can break down under modern demands.

Key risks include:

• No policy enforcement: Files move between people and machines without any central oversight or approval flow
• Unverified content: Executables, macros, and archives go unchecked; often scanned once (if at all) using a single AV engine
• Manual steps and delays: Every file upload or download increases the risk of error, loss, or exposure—especially across IT-OT boundaries

The 2025 IBM X-Force report confirms what CISOs already suspect: “Threat actors are using valid credentials to log in, exploit unpatched vulnerabilities ... with or without AI assistance,” all the while manufacturing remains the top-targeted industry for ransomware. Without role-based access and scanning at every transfer point, attackers only need one unmonitored connection to get into the system.

The bottom line: legacy transfer tools may appear low-cost, but the risk of downtime, data loss, or a failed audit makes them one of the most expensive systems in your plant. It’s time to assess whether your current file transfer practices can keep pace with AI-driven workflows, compliance expectations, and the increasing need for secure cross-domain collaboration.

In manufacturing, files move constantly between people, systems, vendors, and zones. But that same movement creates a wide and often unmonitored attack surface. Many security incidents begin not with a direct network breach, but with a single malicious file.

Removable media like USB drives are still used to update controllers, transfer logs, or deliver vendor patches. In some cases, shared cloud folders or unencrypted SFTP sessions bridge the gap between IT and OT environments. These file exchanges often lack authentication, inspection, or tracking, leaving the door open for exploitation.

According to the Dragos 2025 OT Cybersecurity Report, 87% more ransomware attacks targeted industrial organizations year-over-year, with manufacturing hit hardest. Attackers exploit weaknesses in unmanaged file transfers between IT, OT, and third parties. All they need is just one executable file to be trusted and passed through unchecked.

Legacy tools may scan for known malware, but that’s no longer enough. Manufacturers need to treat every inbound file as a potential threat, and not just those from untrusted sources, but also those coming from partners or internal teams. Thus, to protect their segmented environments, manufacturers now require enhanced cybersecurity measures, such as:

• Multiscanning: Using multiple AV engines in parallel to improve detection accuracy
• CDR (Content Disarm & Reconstruction): Removing embedded threats by rebuilding file structure
• Adaptive Sandboxing: Executing suspicious files in an isolated environment to detect evasive behavior

These technologies don’t just block known threats. They help defend against zero-days and weaponized files that a single antivirus engine can miss. And they do so automatically, without slowing down operations. With AI and automation amplifying data flows, every file transfer becomes either a potential threat vector or a point of assurance.

The difference lies in whether it’s inspected, controlled, and tracked, which is something best achieved through policy-based solutions like Managed File Transfer (MFT). MFT provides centralized control, access restrictions, and full audit logging across segmented networks.

As data volumes grow and compliance demands tighten, manufacturing leaders must ensure their systems can move files securely, consistently, and with full accountability. To reduce risk and prepare for scalable AI integration, manufacturers should:

• Phase out manual transfers that lack authentication, logging, or verification
• Replace legacy FTP and email-based workflows with centralized, policy-enforced MFT
• Enforce malware scanning and sanitization on all inbound files, including those from known partners
• Ensure full traceability with audit logs, approval workflows, and integration into compliance reporting

These steps don’t just strengthen cybersecurity. They also reduce operational delays, lower the cost of compliance, and improve confidence in the data fueling AI systems and decision support tools.