Storms on the factory floor

ISO 22301 – threats & risks (Clause 8.2: Business impact analysis and risk assessment)

Even a well-run factory can face disruptions. Threats range from equipment failures to human mistakes to supply chain interruptions. Understanding these “storms” lets you prioritise continuity measures and reduce downtime risk.

Key risk categories

  1. Technical failures

    • Controllers, networks, servers, and sensors can fail. A single PLC or SCADA outage can halt production.

    • Checks: Are hardware redundancies and failover systems documented? Are critical updates applied?

    • Typical gaps: Single points of failure, undocumented device replacements, missed patch cycles.

  2. Environmental & physical incidents

    • Power outages, floods, fires, HVAC failures, or extreme temperatures can stop operations regardless of the systems themselves.

    • Checks: Are backup power systems tested? Are environmental monitoring and alerts operational? Are evacuation or shutdown procedures documented?

    • Typical gaps: Untested UPS/generator systems, missing environmental logs, unclear responsibility for physical safety.

  3. Human errors

    • Misconfiguration, procedural mistakes, or absence of key personnel can cause downtime or unsafe conditions.

    • Checks: Are procedures documented and understood? Is cross-training in place for critical roles?

    • Typical gaps: Outdated procedures, single-person dependencies, incomplete training records.

  4. Supply chain interruptions

    • Spares, maintenance contracts, and vendor services are often outsourced; delays can directly impact recovery time.

    • Checks: Are critical suppliers identified? Are alternative vendors or stockpiles planned?

    • Typical gaps: Dependencies on a single supplier, missing spare parts, undocumented vendor recovery times.

  5. Cyber incidents affecting OT

    • Malware, ransomware, or misconfigurations in OT or connected IT can stop production or compromise safety.

    • Checks: Are cyber resilience and recovery integrated into continuity planning? Are incidents mapped to operational impact?

    • Typical gaps: IT/OT continuity not aligned, lack of response procedures for cyber events, missing evidence of testing.

Executive gap‑spotting

  • Impact analysis: Are all threats assessed in terms of operational, safety, and financial impact?

  • Recovery priorities: Are critical functions clearly identified and prioritised for rapid restoration?

  • Cross-dependencies: Are IT, OT, supply chain, and vendor dependencies mapped to avoid cascading failures?

  • Historical lessons: Are past incidents and near-misses documented and used to improve resilience planning?

  • Residual risk: Are threats with high likelihood or impact mitigated, and is any remaining risk understood by management?

Picture each “storm” hitting your factory. Could your operations continue? Could your teams act quickly and effectively? Anything you hesitate on is a gap that must be addressed.