Hiring Juniors in Automation: Risks, Rewards, and Cybersecurity Implications

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Introduction

Hiring junior professionals in automation—especially in PLC (Programmable Logic Controller) and industrial systems—can be a double-edged sword. While they bring fresh perspectives and enthusiasm, their lack of experience can introduce security risks. This article explores the cybersecurity implications of onboarding juniors, best practices for secure automation development, and key technical safeguards.

Learning Objectives

  • Understand the cybersecurity risks of junior automation developers.
  • Learn best practices for securing PLC and industrial control systems (ICS).
  • Implement secure coding and version control in automation environments.

You Should Know

1. Secure PLC Development: Avoiding Common Pitfalls

Juniors often lack awareness of industrial cybersecurity threats. Here’s how to enforce secure coding in PLC environments:

Command: (Structured Text – Secure Input Validation)

IF NOT (InputValue >= MinRange AND InputValue <= MaxRange) THEN 
Output := FALSE; 
LogError("Invalid Input Range"); 
ELSE 
Output := TRUE; 
END_IF;

What This Does: Prevents invalid input attacks (e.g., buffer overflows, out-of-range values).

Step-by-Step Guide:

  1. Define safe input ranges in your PLC logic.

2. Implement error logging to detect anomalies.

3. Enforce input validation before processing signals.

2. Securing Legacy Automation Code

Legacy PLC systems are often vulnerable due to outdated practices. Juniors should be trained in secure refactoring.

Command: (Git for Version Control in Automation)

git init 
git add . 
git commit -m "Initial secure PLC refactor" 
git branch secure-deployment

What This Does: Ensures version control, rollback capability, and audit trails.

Step-by-Step Guide:

1. Initialize Git in the project directory.

2. Commit changes before refactoring legacy code.

  1. Use branches to test security patches before deployment.

3. Network Hardening for Industrial Systems

Juniors may overlook network security in ICS. Use these firewall rules to protect PLCs:

Command: (Linux iptables Rule for PLC Traffic)

iptables -A INPUT -p tcp --dport 502 -s 192.168.1.100 -j ACCEPT 
iptables -A INPUT -p tcp --dport 502 -j DROP

What This Does: Restricts Modbus TCP (port 502) to a single trusted IP.

Step-by-Step Guide:

1. Allow only authorized PLC programming stations.

2. Block unauthorized Modbus traffic.

3. Log dropped packets for intrusion detection.

4. Secure Remote Access to Automation Systems

Juniors might use unsafe remote access methods. Enforce SSH tunneling instead of plain-text protocols.

Command: (SSH Tunnel for Secure PLC Access)

ssh -L 502:localhost:502 user@plc-gateway

What This Does: Encrypts Modbus traffic over an SSH tunnel.

Step-by-Step Guide:

1. Replace direct PLC connections with SSH tunnels.

2. Disable default passwords on PLCs.

3. Use key-based authentication for SSH.

5. Detecting Anomalies in Industrial Networks

Juniors should be trained in monitoring ICS traffic for cyber threats.

Command: (Zeek/Bro IDS for ICS Traffic Analysis)

zeek -i eth0 -C local "Site::local_nets = { 192.168.1.0/24 }"

What This Does: Monitors industrial network traffic for anomalies.

Step-by-Step Guide:

  1. Deploy Zeek on a span port or ICS gateway.

2. Define trusted IP ranges.

3. Alert on unexpected protocol behavior.

What Undercode Say

  • Key Takeaway 1: Juniors can modernize automation security if properly mentored.
  • Key Takeaway 2: Legacy PLC systems require strict version control and input validation.

Analysis:

While juniors bring innovation, their lack of experience in industrial cybersecurity can expose critical systems to attacks. Structured training in secure PLC coding, network hardening, and anomaly detection is essential. Companies must balance innovation with risk mitigation by pairing juniors with senior mentors.

Prediction

As automation systems increasingly integrate with IT networks, cybersecurity threats will grow. Juniors trained in secure-by-design principles will become crucial in defending industrial infrastructure against sophisticated attacks. Companies that invest in structured cybersecurity training for junior automation engineers will gain a competitive edge in secure Industry 4.0 deployments.

IT/Security Reporter URL:

Reported By: Thomas Benninger – Hackers Feeds
Extra Hub: Undercode MoN
Basic Verification: Pass ✅

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