Business Continuity in Manufacturing: Best Practices & Backup Solutions for 2026

Threats to production

One of the most common threats in manufacturing is a breakdown in production equipment. That’s why manufacturers invest heavily in human capital, hiring skilled engineers and other specialists who can rapidly make repairs when needed.

However, manufacturers should be investing just as wisely in protection against other threats that are as destructive:

• Cyberattacks and malware: Attacks like ransomware can destroy your data in a matter of minutes, making your critical applications unusable and locking you out of the files that your company runs on.
• IT disruptions: Data loss, network outages, server failure, software errors – each of these disruptions can have a severe impact on manufacturing operations, especially if there are no continuity systems in place.
• Natural disaster: Severe weather events and other natural disasters pose a major risk to your manufacturing equipment and personnel. If a factory is destroyed, and there’s no backup plan, operations may never resume,
• Fire & smoke: Even if a fire is contained, smoke damage can derail your production schedule and cause a health risk to workers. Manufacturers must not only comply with local fire codes to prevent accidents, but also must have a continuity plan that ensures production can continue soon after a disruptive incident.
• Flooding: Whether due to a severe weather event or interior damage, such as a pipe break, flooding inside a building can cause costly damage to manufacturing equipment and processes.
• Utility outages: An extended power outage or loss of other critical utilities like natural gas can result in lengthy manufacturing interruptions. Having access to redundant systems is essential for manufacturers that cannot afford to wait on utility companies to restore service at their leisure.

A $2.5 billion nightmare

One of the most recent, high-profile manufacturing disruptions was the 2025 cyberattack on British automotive giant Jaguar Land Rover (JLR) – from which the financial fallout was still felt a year later. The attack disrupted the company’s manufacturing, logistics and dealership operations for weeks. Internal IT networks went offline. Global production lines came to a complete standstill (and thousands of workers were told to stay home).

The cascading outage also sidelined thousands of connected companies across the UK. Initial estimates put the financial impact of the attack at about £50 million per week for JLR. By the end of fiscal year in March 2026, JLR’s total annual revenue had dropped nearly 21% to £22.9 billion. A report by Cyber Monitoring Centre (CMC) also revealed that the attack cost the UK economy £1.9 billion (roughly $2.5 billion USD).

Here’s how the impact added up, according to the CMC and government assessments:

• £1.9 billion in estimated economic damage across the broader UK supply chain
• 5,000 supply chain businesses paralyzed by canceled or delayed orders
• £1.5 billion in emergency government loan guarantees required to stabilize the vendor network

These are staggering figures, especially considering that the production pause was initially believed to last only a few days. These numbers should alarm every manufacturer, especially smaller companies that don’t have the same financial resources to survive such an outage. 

Recent ransomware attacks in manufacturing

Over the last few years, ransomware in the manufacturing sector has been rampant. Boeing, Nissan, Mondelez, Renault and Merck are just a few of the big-name producers that have been derailed by infections.

Consider these recent statistics:

• In a 2025 survey, 40% of manufacturing and production organizations said their data was encrypted in a ransomware attack, according to figures from Sophos.
• Ransomware has cost the manufacturing sector $17 billion in downtime from 2018 to 2024, according to Comparitech.
• In the first quarter of 2025, ransomware attacks surged 46% across manufacturing and industrial sectors, according to Honeywell.

Vulnerabilities in manufacturing

Hackers typically target manufacturers because they know these companies will often pay higher ransom demands if their production is halted. But that’s only part of it. Experts say that manufacturing companies also tend to be more vulnerable to attack, due to the use of outdated software and unpatched operating systems. Hackers then take advantage of these flaws (or use deceptive attacks like phishing emails) to infiltrate the company’s network – which is why manufacturers are urged to use robust threat-detection solutions like RocketCyber MDR (see RocketCyber pricing).

Despite the fact that some subsets of manufacturing, such as pharmaceuticals, are highly regulated by federal laws, the industry does not face the kind of strict business continuity regulation as sectors like healthcare do.

Manufacturing-Focused Example Scenario: A ransomware attack encrypts production scheduling systems and shared engineering files, forcing a manufacturing facility to pause operations while systems are restored.

Without rapid recovery, production delays lead to missed delivery deadlines, overtime costs, and strained customer relationships.

Manufacturing disaster recovery plan template example

A disaster recovery plan (DRP) is a comprehensive document that outlines an organization’s protocols for responding to an operational disruption. A DRP is sometimes also referred to as a business continuity plan (BCP), although the two documents are actually a bit different. (Disaster recovery is a subset of business continuity and is often focused specifically on IT-related disasters.)

Every manufacturing company—and indeed all organizations, regardless of industry—should have both a BCP and a DRP to ensure their organization is prepared for every possible disaster.

While every company is unique, a basic manufacturing disaster recovery plan template should include the following sections:

 Tip: Disaster recovery plans are sometimes included within the more comprehensive business continuity plan. If you’re developing a BCP, check out our business continuity plan template.

A lack of redundancy

Creating operational redundancy is one of the best things manufacturers can do to ensure continuity after a disruption.

• If equipment fails, there should be a backup (or parts readily available for quick repair).
• If critical data is lost, there should be a backup.
• If employees go on strike, there should be others who are already trained and can quickly fill in their shoes.
• If an entire facility is destroyed, there should be another location ready to go.

Understandably, small manufacturers won’t have the resources for Redundant Everything. However, they should still have a plan.

Anticipating a potential disaster, and knowing how to adequately respond, is the best thing a company can do to avert a prolonged disruption (which is why a thorough risk assessment and impact analysis are so important).

For example: a small manufacturer might not be able to afford secondary production equipment that just sits around in case of a disaster. However, they should absolutely have a plan for repairing such equipment, or quickly acquiring new equipment, or leasing some through a third-party facility if needed. There must be a plan for how the business will keep running.

The need for better data backups in manufacturing

We’ve mentioned how ransomware and other forms of data loss can threaten manufacturers. Whether it’s customer records, inventory data, order information or the software that keeps everything running, a sudden loss of this vital data can bring operations screeching to a halt.

Even with robust cybersecurity, having backups is essential. But also, it matters how that data is backed up and how dependable it is when you need it most. Too many manufacturing companies are relying on outdated backup technologies that are prone to failure during recovery and also vulnerable to threats like ransomware.

For stronger data protection, companies should be deploying advanced disaster recovery systems that provide:

• Higher backup frequency: The ability to perform backups more often (every few minutes, if necessary), so that data loss is minimized when you need to roll back to the last recovery point.
• Faster access to data: The ability to instantly recover lost files or even whole servers via virtualized backups or other recovery methods. With virtualization, you don’t need to wait for a full restore to start using your critical applications again – you can spin up a machine in seconds.
• More resilient backups: Dependable backups that don’t fail during recovery and are protected by automated checks that validate the integrity of the data. For example, Datto backup solutions use image-based backups that capture a complete picture of a protected server at every backup, without being dependent on previous backups.
• Hybrid cloud protection: Backups stored locally and in the cloud to create redundancy in case on-premise infrastructure is destroyed.
• Built-in ransomware detection: An added layer of ransomware protection built into the backup system, a la the Datto SIRIS and ALTO, which automatically scan each backup for signs of an infection.
• SaaS data protection: As more manufacturers leverage SaaS applications to support their operations, protecting this cloud data has become just as important. Using tools like Datto SaaS protection to back up data in Microsoft 365 and Google Workspace is critical.

Now more than ever, manufacturers depend on data to keep production moving.  A failure to adequately protect that data is just as risky as failing to safeguard any other aspect of your operations.

Without proper planning, combined with detailed protocols and dependable BC/DR technologies, producers leave their companies at risk of a catastrophic break in continuity. (For stronger BC/DR, request Datto SIRIS pricing for your organization.)

Best backup solutions for manufacturing firms

There is no one-size-fits-all approach to business continuity in manufacturing. The factory floor of a 500-person aerospace parts manufacturer has vastly different IT requirements than a 15-person local fabrication shop.

Because manufacturing environments often deal with a mix of modern cloud applications, resource-heavy CAD/engineering workstations and legacy production control servers, your backup strategy needs to match your infrastructure. Here is a look at four different approaches using top-tier solutions from the Datto/Kaseya ecosystem:

Comparing BC/DR Approaches – A Quick Overview

*Datto SIRIS and Unitrends can also be deployed as virtual appliances, allowing backup and recovery infrastructure to run in VMware, Hyper-V or cloud-hosted virtual environments instead of dedicated physical hardware.

1. Datto SIRIS (The All-in-One Powerhouse)

Datto SIRIS is a robust, image-based Business Continuity and Disaster Recovery (BCDR) appliance. It takes frequent snapshots of your entire server environment and stores them locally and in the Datto Cloud. Its biggest advantage for manufacturers is “instant virtualization”—if a primary server fails, you can spin up a virtual replica directly on the SIRIS appliance (or in the cloud) in minutes, keeping the production line moving while the original hardware is repaired.

• Starting Price Range: Hardware appliances generally start around $1,000–$1,500, with monthly cloud service fees starting around $150–$300/month (scaling with your data storage and retention needs).
• Tradeoffs: It typically requires a higher upfront investment for the physical appliance (and for the advantage of being a tightly integrated all-in-one solution).
• Who it’s for: Small, medium or large manufacturers who cannot afford to lose a core server (like an ERP or inventory management system) for more than an hour.
• Who it’s not for: Highly decentralized teams without a central office or server room, or extremely budget-constrained micro-businesses.

For more information, request Datto SIRIS pricing for your organization.

2. Datto ALTO (The Small Business Entry Point)

Datto ALTO provides the same image-based, enterprise-grade data protection as SIRIS but is scaled down for smaller operations. Instead of virtualizing downed servers locally on the device itself, ALTO relies on hybrid virtualization (using another machine on your local network) or spinning up the server in the Datto Cloud.

• Starting Price Range: The hardware is often provided for free (or at a very low cost) with a time-based service commitment. Monthly cloud service fees generally start between $80–$150/month.
• Tradeoffs: Because it lacks the heavy computing power to virtualize a server locally on the box, recovering a failed system can take longer than it does with SIRIS, especially if you have to rely on cloud virtualization over a standard internet connection.
• Who it’s for: Smaller machine shops, local fabricators or branch locations with a limited IT budget and a small data footprint (typically under 2TB).
• Who it’s not for: Facilities that require instant, local recovery to prevent massive production bottlenecks, or businesses managing massive CAD file repositories.

For more information, request Datto ALTO pricing for your organization.

3. Datto Endpoint Backup (The Direct-to-Cloud Solution)

Not all critical manufacturing data lives on a server. Sales directors travel with sensitive client contracts, and field engineers often have localized schematics stored on their laptops. Datto Endpoint Backup is a software-only solution that backs up Windows and Mac PCs directly to the Datto Cloud, no matter where the device is located.

• Starting Price Range: Typically about $3-$5 per device, per month.
• Tradeoffs: This is strictly for individual workstations, laptops and servers that are not protected by other backup solutions. It also does not offer instant virtualization; recovery involves downloading files or performing a bare-metal restore to a new PC.
• Who it’s for: Manufacturing sales teams, traveling executives, and field engineers who frequently work off-network but carry critical company data.
• Who it’s not for: Protecting the central factory floor control systems, shared network drives, or core business servers.

For more information, request Datto Endpoint Backup pricing for your organization.

 4. Unitrends Enterprise BCDR (The Complex Environment Specialist)

Manufacturing IT environments are notorious for being a patchwork of old and new technologies. Unitrends excels in heterogeneous environments, offering deep integration with over 250 operating systems, applications, and hypervisors. Whether you have modern VMware setups running alongside legacy physical Windows servers or specialized Linux-based production controllers, Unitrends can unify the backup process into a single pane of glass.

• Starting Price Range: Entry-level physical appliances typically start around $1,500–$2,000+, alongside varying software and cloud storage subscription tiers.
• Tradeoffs: It features a steeper learning curve than Datto SIRIS and can be more complex to deploy initially.
• Who it’s for: Manufacturers with complex, legacy or highly diverse IT infrastructure that includes multiple operating systems and non-standard servers.
• Who it’s not for: Smaller operations with a very standard, simple, Windows-only IT footprint where Unitrends’ advanced capabilities would be overkill.

For more information, request Unitrends pricing for your organization.

The case for cyber insurance in manufacturing

Even with backups, manufacturers need to be prepared for the risk of costly cyberattacks such as ransomware. As such, cyber insurance has become an increasingly common layer of protection for manufacturing companies (and other sectors) to recoup losses that do occur. This is especially critical for smaller manufacturers that do not have the financial resources to withstand an extended outage or large-scale data loss.

Sonit Jain, CEO of GajShield Infotech, writes for CXO Outlook: “Cyber insurance is needed for the following liability coverage in case a cyber-attack hits a manufacturing company’s business architecture, [including] first-party liabilities such as credit monitoring, identity theft, procurement data restoration, contact centre set up, direct ransomware attacks and similar others.” Additionally, he writes, insurance can provide coverage for the costs of lawsuits, regulatory investigations and electronic and social media liability.

Business continuity plan example for manufacturing companies

Manufacturing businesses face unique continuity challenges. Production downtime, supply chain disruptions, equipment failures, and cyber incidents can halt operations, delay shipments, and create costly ripple effects across customers and vendors.

A manufacturing business continuity plan must account for both IT systems and operational technology to keep production moving during disruption.

Throughout this post, we’ve highlighted some of the core components of a business continuity plan for manufacturers. But if you’re developing a BCP for the first time, then it may help to have a high-level overview of what you’ll need to create the plan. Here is a checklist of basic questions you can use to get started:

• Who will create the BCP? Which individual(s) will manage it over time? Will they have access to different department heads to gather the information they need to develop the plan?
• What is the objective of the BCP? Is it focused on a single aspect of operations or the entire company?
• How often will the plan be reviewed? When should it be updated?
• What are the risks? Which threats pose a risk to production or critical business operations?
• What is the impact of those threats? What do those events actually look like? What will they cost? What reverberations will they have on other aspects of the business?
• How can they be prevented? What systems or strategies can prevent these disruptions from occurring in the first place?
• What is the best response? When disruptions occur, how can the impact be mitigated? Which steps can shorten the duration?
• How can the business recover? What are the procedures for disaster recovery? Which systems should be leveraged? What contingencies are needed?

What a Manufacturing Business Continuity Plan Should Address

• Access to production and scheduling systems
• Protection of engineering and design files
• Recovery timelines for ERP and MES platforms
• Communication with suppliers and customers
• Backup access to critical operational data

Related reading:

• The Ultimate Business Continuity Plan, Guide Template & FAQ [Updated]
• Business Continuity Planning: How to Plan for Disruptions in 2026

Frequently asked questions (FAQ)

1. Why is a business continuity plan so important for manufacturing companies?

Manufacturing companies rely on continuous operations to meet production targets and satisfy customer demands. A BCP ensures that, in the event of a disruption, essential operations can continue or be quickly restored, minimizing downtime, financial loss and potential damage to brand reputation.

2. What are the 3 main areas business continuity focuses on?

Business continuity has three main goals: 1) identifying risk, 2) preparing for disaster, 3) restoring operations after a disruption. Together, these three main areas of focus help an organization to understand the threats to its operations and ensure that it can continue operating.

In manufacturing, business continuity planning is critical for preventing disruptions to production and responding swiftly to any event that disrupts manufacturing processes.

3. What are examples of business continuity?

Business continuity refers to any situation in which a business has implemented systems, failsafes or procedures for maintaining operations after a disruption. In manufacturing, some examples include:

• Restoring data backups after data loss
• Using backup generators during utility outages
• Making quick repairs to restore damaged production lines
• Activating secondary manufacturing sites
• Rapid hiring initiatives during a worker strike

4. What is BCP in manufacturing?

In manufacturing, BCP stands for business continuity plan, which is a planning document that identifies the systems and procedures for maintaining operations during a disruptive event. A typical BCP includes detailed risk assessments, impact analyses and protocols for disaster prevention, mitigation and recovery.

5. What are the key components of a business continuity plan for manufacturing?

A BCP for manufacturing typically includes:

• Risk assessment and impact analysis
• Response strategies for different types of disruptions (e.g., fire, flood, cyberattack)
• Recovery strategies for critical operations
• Communication plans for employees, suppliers and customers
• Roles and responsibilities of key personnel during a disruption
• Testing and training procedures to ensure preparedness

6. What is an example of a manufacturing-specific disruption that a business continuity plan should cover?

A common example would be a supply chain interruption, where key raw materials or components are not available due to vendor issues. A BCP would include strategies to find alternative suppliers or adjust production schedules to mitigate the impact on operations.

7. How does a business continuity plan address equipment breakdowns in manufacturing?

A manufacturing BCP would include preventive maintenance schedules to reduce the risk of equipment failure. It would also outline steps to quickly repair or replace critical machinery and maintain production by using backup equipment or outsourcing specific production tasks.

8. What role does IT play in a manufacturing BCP?

IT is crucial in modern manufacturing operations. A BCP would include data backup strategies, disaster recovery plans and cybersecurity measures to ensure that critical IT systems can be restored and protected from breaches, ensuring production continues with minimal interruption.

9. How often should a manufacturing company update its BCP?

A BCP should be reviewed and updated regularly—at least annually or after any significant changes in the business, such as new equipment, updated technology or major organizational shifts. Additionally, the plan should be tested regularly to ensure its effectiveness.

10. What are the potential costs of not having a BCP for a manufacturing company?

Without a BCP, a manufacturing company could face significant financial losses due to extended downtime, lost production, contract penalties, customer dissatisfaction and possible regulatory fines. In the long term, it could also damage the company’s reputation and lead to loss of business.

11. Can a BCP help with compliance and regulatory requirements in manufacturing?

Yes, many regulatory bodies require companies, including manufacturers, to have BCPs in place to ensure that they can continue operations in the event of disruptions. A well-developed BCP can help a company meet compliance standards, avoid penalties and reduce risks associated with regulatory audits.

12. What is the biggest business continuity risk for manufacturing companies?

Downtime is the biggest risk. Even short outages can halt production, delay shipments, and create cascading supply chain issues.

13. How does backup and recovery support manufacturing continuity?

Backup and recovery ensure critical production data, scheduling systems, and files can be restored quickly after disruptions, minimizing downtime and operational impact.

Conclusion

A failure to maintain business continuity in manufacturing can be disastrous. Regardless of the source of the disruption—ransomware, equipment malfunction, utility outage or some other threat—manufacturers stand to lose millions when production lines are halted. As such, companies must take business continuity planning seriously.

Manufacturers can significantly curb the risk of operational downtime by implementing sound disaster recovery procedures and IT systems such as data backup. So when disaster strikes, companies can keep their doors open and keep production moving.

Learn more about data backup for manufacturing

Get more information on disaster recovery solutions that can protect your manufacturing operations from data loss and operational downtime. Set up a call with one of our data protection specialists here at Invenio IT or contact us for more information. Call us at (646) 395-1170 or email success@invenioIT.com.