Cyber threats are a major concern for UK manufacturers. Recent research has shown that manufacturing is the sector that is most targeted by ransomware. In a UK ransomware mid-2024 report, manufacturing was “consistently the most targeted sector both in the UK as well as globally”. The UK’s small manufacturers (50-200 workers) are particularly hard hit, with an average of 10% more attacks than the overall average. IBM X-Force reports manufacturing has been the most targeted industry for four years in a row, while the World Economic Forum says the cost of a data breach is increasing by 125% annually. A UK official survey revealed that ransomware was affecting a larger proportion of companies than previously thought. The percentage of businesses affected by the malware nearly doubled between 2024 and 2025, from less than 0.5% to about 19,000 firms.
The stakes are high: a medium-sized UK company faces £4.3 million of costs if there is a serious breach. Even a few hours of downtime in manufacturing can cost millions of dollars. Margins are thin, and production delays are costly. Jaguar Land Rover’s September 2025 incident is a cautionary tale. JLR’s hacking attack forced shutdowns of several weeks at factories in the UK, China, and other countries, showing how a single breach could disrupt thousands of jobs and stop production of hundreds of vehicles per day. The attack occurred during the UK registration season, which caused delays. JLR produced 1,000 vehicles per day (96m turnover), so even a short outage had a huge impact.
This attack showed that rapid reaction could limit the damage. JLR’s IT department isolated the affected systems quickly, stopping attackers’ lateral movement. This prevented even greater losses. Since then, their example has been used to promote Zero Trust and proactive auditors in automotive settings.
The lesson for UK SMEs as well as large companies is that digital transformation in manufacturing brings both productivity gains and new cyber risks. Penetration tests, compliance audits, and AI-driven monitors are essential for uncovering these risks before criminals take advantage of them. We demonstrate in the case study below how a UK-based car manufacturer used these exact services to stop a major ransomware threat using realistic threat scenarios. The attack was identified and contained early, avoiding a costly compromise.
Case Overview: EuroCar Ltd. (UK)
EuroCar Ltd. is a UK-based automaker that produces mid-range electric cars. The company has two plants in the Midlands and employs 800 people. It outsources its IT infrastructure but still maintains some legacy systems. EuroCar’s CIO hired Gorilla360, a UK provider of cybersecurity services, in late 2024 to perform a complete security audit. The audit included penetration testing of network, web, and OT systems, a gap analysis (ISO 27001/IEC 62443, NIS2/GDPR), and the deployment of AI-based tools. The goal was to improve overall resilience and identify hidden vulnerabilities.
The audit revealed several alarming findings. Summary:
- Legacy systems that are not patched: Many Windows Servers and industrial control systems are outdated by years. There were vulnerabilities like CVE-200-0796 (SMBGhost) and CVE-200-0708 (“BlueKeep”), which could be used to enter ransomware.
- Insecure remote access: EuroCar’s remote maintenance interface only used basic passwords, and there was no multi-factor authentication. This is a ransomware vector that has been used for many years (compromised RDP credentials have led to numerous breaches).
- Inadequate network segmentation. The IT (office) and the OT (manufacturing) networks were not segregated properly. One breach in the administrative LAN can easily spread to the production environment.
- Incomplete recovery and backup plan: Backups were available, but they were not connected to the network and had never been tested in disaster conditions. This is a major gap for ransomware preparedness.
- Employee Phishing Risk: An audit team simulated phishing tests and found that 8% clicked on the bait link. This real-world testing highlighted the human factor.
These weaknesses were discovered by the penetration testing, which simulated attacker techniques. URM Consulting says that such testing “identifies security vulnerabilities” and allows organizations to address them before criminals attack. The EuroCar pen-test team gained access to the system via an unpatched RDP server. They then escalated their privileges by using unpatched systems. Finally, they demonstrated how quickly ransomware could be installed if the attack was left unattended.
EuroCar’s sophisticated manufacturing environment is illustrated by the image above (automated assembly robotics). The automation not only increases efficiency, but also demonstrates how closely connected the production systems are. A breach at the OT layer (Operational Technology) could stop the assembly line. EuroCar’s audit prioritized locking these systems.
Audit Remediation Strengthening Defences
EuroCar and Gorilla360 developed a remediation plan that included multiple components:
- Update and patch: All vulnerable systems identified are patched or isolated. Servers that were no longer supported by the vendor have been retired or replaced. The Gorilla360 team verified that critical patches had been applied and automated patch management for future updates was implemented.
- Secure Remote Access: Remote access was secured immediately by enabling MFA. Strong password policies were also implemented. Remote admin ports that were not necessary were closed, and a VPN with strict two-factor authentication was made mandatory for off-site access.
- Network segmentation. The IT network and the OT network were segmented by firewalls and virtual local area networks (VLANs). The sensitive controllers on the production line are placed in an isolated network requiring special credentials. This prevents a network breach at the office from directly reaching the factory floor.
- Redesign of EuroCar’s backup strategy: EuroCar redesigned its backup architecture. The backups were transferred to a vault that was offline and restored using restore drills. To minimize downtime, a ransomware response plan has been documented and practiced with staff.
- User Awareness Training: Due to the high “click-rate” of phishing, all employees were required to attend mandatory cybersecurity training. They learned about phishing signs as well as reporting procedures.
Gorilla360 deployed its AI-based threat detection across EuroCar’s infrastructure to ensure constant vigilance. This system uses machine learning to detect anomalous behavior. It monitored network traffic to detect unusual SMB activity (file sharing) and scanned emails for hidden threats. It can also analyze industrial logs in a way that is beyond the scope of a manual review. The AI system acted as a 24/7 guardian, alert to early signs of ransomware intrusion.
Gorilla360 claims to have industry-leading performance. It boasts “99.9%” threat detection on monitored endpoints and a threat response average time of 2.3 seconds. (compared to an industry average of 197 days). This means that the system will alert administrators to suspicious activities almost immediately. In 90 days, customers typically see a 85% decrease in security incidents. These metrics demonstrate the power of combining AI and security expertise.
Attack Incident: Ransomware Attempt & Response
EuroCar’s system was put to the test six months after the audit in March 2025. A targeted phishing (apparently sent by an engineer) tried to deliver a ransomware strain disguised in a PDF invoice. The engineer was not to click the link, thanks to his prior training. On the same day, the Gorilla360 AI flagged unusual login attempts to a backup domain control. In a separate hack, the old credentials of a vendor were compromised. An automated login attempted to access critical systems.
The AI platform immediately generated a high-priority alert thanks to the new monitoring. The Gorilla360-trained SOC team was able to isolate the accounts within seconds. The team found a ransom note on a shared hard drive that indicated the start of encryption. Crucially:
- Immediate containment. Due to network segmentation and automated responses, the rogue processes could not jump from backup servers to main production servers. The critical OT systems remained untouched.
- Automated Action: In real-time, the AI system blocked the suspected malware binary. It also locked the account of the user. The MDR team (Managed Detection and Response) activated preconfigured playbooks to shut down specific network shares and prevent file encryption.
- Full recovery: Backups isolated from each other were used to restore a single encrypted file. EuroCar did not pay any ransom because the attacker only compromised a portion of one system. The total downtime was less than two hours and limited to an investigation period offline, which is far below the multiple-day closures that are seen with more severe incidents.
Shortly, the audit conducted earlier and the layers of defenses in place now allowed a ransomware attack that could have been devastating to be detected and neutralized before it had a chance to take hold. There were no encrypted production files. No ransom payments. And no production shutdowns for a long time. EuroCar’s rapid containment was praised by an expert summary as “exemplifying effective incident management practices”, similar to Jaguar Land Rover’s reaction in 2025.
Results and Business Impact
EuroCar transformed a potential crisis into a minor event by proactively auditing and strengthening its security. Key benefits include:
- Financial loss avoided: Only a few hours of IT staff time and verification were required to detect the attempted breach. Global ransomware incidents, on the other hand, often result in downtimes exceeding one day. EuroCar is so large that a single day of downtime could have cost more than PS1 million. This audit likely saved millions of pounds in potential losses.
- Retained customer trust. EuroCar avoided reputational damage by not disclosing any breaches to customers or regulators.
- Confidence in faster recovery: EuroCar’s tested backups, incident plan, and test data meant that EuroCar was able to restore critical data without negotiation, even if it had been locked. Investors are more confident with this kind of resilience.
- Continuous Improvement: Post-incident reviews fed into audit cycles. EuroCar has committed to continuous penetration tests and AI scanning, which ensures that their defenses are evolving with new threats.
Gorilla360 services have created a “force multiplier effect” in general, especially the AI-driven continuous audits combined with one-time reviews. EuroCar’s CEO later stated that the program “made all the difference” between their cyber strategy being chaotic or confident.
The Best Practices and Key Lessons
This case illustrates several lessons that UK SMEs and companies in the manufacturing sector can learn from:
- Audits Uncover Hidden Risks. Regular cybersecurity audits (including penetration tests and compliance reviews) identify weak points that would otherwise be invisible. EuroCar, for example, did not know that its RDP setup or backup plan was vulnerable until an audit revealed it. Security experts can identify vulnerabilities and weaknesses through penetration testing.
- AI Monitoring is Critical: Automated AI detection significantly accelerates responses. Machine learning, as Gorilla360 points out, can detect anomalies much faster than manual methods. In this instance, the AI system detected the intrusion within seconds and stopped lateral movement. It is possible that a human team would not have spotted the intrusion attempt until encryption began.
- Layered Defence (Zero-Trust): The concept of zero-trust, assume breach, and segment networks accordingly, has paid off. EuroCar’s network was segmented, so an attacker from one side could not easily move to the other. Experts have recommended that we move away from perimeter defenses and instead verify every entry.
- Regular Training for Employees: Technical defences are only as good as the staff who are vigilant. The audit’s testing of phishing and the follow-up training reduced risk. In fact, an employee who was well informed foiled one attempted phishing attempt. Constant awareness programs help keep the human firewall in place.
- Compliance with Standards and Regulations: EuroCar was also audited against ISO 27001 (since it is an automotive manufacturer that supplies EU markets) and UK GDPR. These compliance items can be addressed (e.g., by establishing an Incident response plan, not only did we reduce legal risks but also closed security gaps in an indirect manner. Gorilla360’s approach aligns audits explicitly with regulations (GDPR and NIS2) in order to cover all bases.
Finally, partnering up with security experts can help to amplify internal efforts. EuroCar’s Director of IT noted that “Gorilla360’s analysts, cutting-edge AI, and tools were a game changer, we got enterprise protection at SMB scale.”
Final Steps and Conclusion
Ransomware poses a real and immediate threat to UK manufacturing. The EuroCar case shows that prevention pays off. By investing in a comprehensive cybersecurity audit and cutting-edge AI monitoring, EuroCar neutralized an attacker that could have cost the company millions.
The following are the steps that UK companies in similar industries can take:
– Schedule audits regularly: Identify vulnerabilities and fix them through penetration testing and regulatory compliance checks.
– Leverage AI tools: Deploy real-time detection systems for continuous monitoring.
– Implement security hygiene: Patch quickly, use MFA, and segment networks.
– Train your staff: Run phishing simulations.
Cybersecurity is not just a tech issue. It’s a business one. Executives and CIOs must prioritize cybersecurity at the board level. Gartner analysts say that breaches aren’t a matter of whether or when. Being prepared is the key. EuroCar’s proactive audits made “when” a footnote, not a disaster.
AI Cybersecurity Services by Gorilla360 are a great option for UK car manufacturers, as well as other SMEs looking to improve their security. Their solutions offer a quantifiable return on investment, such as e.g. In 90 days, clients typically see an 85% reduction in incidents. These services, such as AI-driven scanning and compliance alignment detailed on Gorilla360’s website, can help firms uncover hidden risks and lockdown systems before attackers strike. Do not wait until an attack occurs. Schedule a comprehensive cybersecurity audit and AI-driven risk assessment today with Gorilla360 to ensure that your operations remain safe and resilient against threats.
