Modern manufacturers rely on fast, efficient, and highly connected supply chains to stay competitive. But when every system is connected, from inventory tracking to vendor communication and logistics, the entire operation becomes more vulnerable to disruption.
In this blog, we’ll explore how gaps in your IT approach can threaten supply chain performance and what you can do to build a stronger, more resilient infrastructure.
1. The Increasing Digital Dependency of the Supply Chain
Today’s supply chains are powered by advanced digital systems. Tools like Enterprise Resource Planning (ERP) software, Internet of Things (IoT) devices, automation platforms, and vendor portals keep operations running efficiently by enabling real-time data sharing, remote monitoring, and precise control over production.
These technologies reduce manual errors, shorten production timelines, and improve responsiveness across the entire supply network. But as digital dependency grows, so does exposure to IT disruptions. A single point of failure, whether it’s a malware attack on your ERP system or a power outage that affects critical IoT devices, can quickly disrupt operations, delay deliveries, and lead to significant financial losses.
2. Common IT Weaknesses That Threaten Supply Chain Continuity
Even the most advanced supply chain can be brought to a halt by IT gaps. Here are some common weaknesses that put continuity and performance at risk:
Outdated Systems & Software
Legacy tools may still function, but they often lack the speed, support, and compatibility needed to keep up with modern supply chain demands. They can increase the risk of downtime, limit data sharing across systems, and make it harder to integrate with newer technologies.
Inadequate Cybersecurity
Cyberattacks like ransomware and phishing are increasingly targeting manufacturing companies. A single attack could halt production lines, compromise vendor relationships, and damage customer trust. Without strong cybersecurity in place, the impact of these threats can escalate quickly.
Poor Network Visibility
Without clear visibility into the network and connected systems, it becomes difficult to detect threats or identify performance issues. This blind spot delays response times and increases the risk of prolonged disruptions.
No Backup or Disaster Recovery Plan
What happens when a critical system goes down? If there’s no well-documented and tested disaster recovery plan, the result is often missed shipments, damaged customer relationships, and significant revenue losses.
Limited Vendor Risk Oversight
Partners and third-party systems are part of the picture too. If their security is lacking, it can easily affect your operations. Without oversight, they could open the door to data loss or cyberattacks.
3. Real-World Consequences of IT Failure in Manufacturing
IT disruptions can bring supply chains to a standstill. In late 2024, Blue Yonder, a major supply chain software provider, was hit by a ransomware attack that impacted companies like Starbucks and UK-based grocery chains Morrisons and Sainsbury’s. Starbucks was forced to switch to pen and paper for scheduling and payroll at thousands of locations. In the UK, warehouse systems went down, delaying the distribution of fresh produce and leaving shelves understocked.
Events like this show how quickly a single IT failure can ripple across multiple operations. The cost of downtime in manufacturing is estimated at more than $260,000 per hour, and the average supply chain disruption can take weeks to resolve.
4. Signs Your IT Strategy Isn’t Aligned with Supply Chain Resilience
How can you tell if your IT strategy isn’t meeting supply chain needs? Below are some red flags to watch for:
- No 24/7 System Monitoring: Threats can arise at any time. Without constant visibility, problems like downtime or breaches may spiral out of control.
- Always in Crisis Mode: If the IT team is constantly reacting to problems instead of preventing them, it suggests the strategy is focused on short-term fixes rather than long-term resilience.
- No Disaster Recovery Plan: Missing documentation or untested recovery procedures leave you exposed during crises.
- Fragmented IT Oversight: When IT visibility is scattered across vendors, facilities, or regions, communication breaks down. This makes it harder to identify risks early or coordinate an effective response.
If any of this resonates with your organization, it may be time to reassess your IT approach.
5. What a Resilient, Supply-Chain-Safe IT Strategy Looks Like
A supply chain is only as strong as the systems behind it. Building a resilient IT strategy means putting the right protections, processes, and technologies in place. Here's what an optimal strategy includes:
1. Integrated Systems
Tools and platforms are connected in one centralized environment. Data flows smoothly between departments and vendors, helping teams act faster and spot problems early.
2. Regular Updates & Maintenance
Every system and device is kept current with routine updates. Maintenance is planned and proactive, reducing the risk of unexpected downtime or security issues.
3. Zero Trust Security Model
Access is never assumed. Every user and device must be verified before connecting to the network, whether internal or external. This limits exposure and keeps threats contained.
4. Cloud-based Backups with Disaster Recovery
Backups are stored in the cloud and regularly tested. If systems go down, there’s a clear recovery process in place to restore operations quickly and avoid long delays.
5. Proactive Vendor & Endpoint Risk Assessments
External systems and connected devices are continuously evaluated. Third-party access is tracked and reviewed just like internal systems to prevent gaps in security.
How EpiOn Helps Manufacturers Build Safer, Smarter IT Environments
At EpiOn, we understand the critical role IT plays in maintaining a resilient supply chain. With our expertise, we help manufacturers reduce downtime through 24/7 system monitoring, strengthen cybersecurity with a proactive defense approach, and simplify compliance by translating complex regulations into clear action plans. Our strategies are tailored to your business needs and built to support your operational goals, both now and as your supply chain evolves.
Not sure if your IT strategy is aligned with your supply chain goals? Schedule a consultation or request an IT audit to get started today.
