Cyber threats have become a top concern for UK manufacturers. Recent research shows manufacturing is now the most targeted sector for ransomware and cyberattacks. A mid-2024 UK ransomware report found manufacturing “has consistently been the most highly targeted sector in the UK and globally”. Small UK-based manufacturers (50–200 employees) are hit especially hard, about 10% more often than the general average. This aligns with broader cyber surveys: IBM X-Force notes four consecutive years of manufacturing as the most attacked industry, and the World Economic Forum reports that the average cost of a breach is rising 125% per year. In fact, an official UK survey found that the proportion of businesses experiencing ransomware roughly doubled from under 0.5% in 2024 to 1% in 2025 (about 19,000 businesses), and in manufacturing specifically, 60% of firms had a security incident (one-third suffering financial or operational loss).
These stark numbers underscore the stakes: an average medium UK firm now faces roughly £4.3 million in costs from a serious breach. In manufacturing – where margins are tight and production delays are costly – even a few hours of downtime can mean millions lost. The Jaguar Land Rover incident of September 2025 provides a cautionary example. JLR’s cyberattack forced multi-week shutdowns at plants in the UK, China and elsewhere, illustrating how a single breach can disrupt thousands of jobs and block production of hundreds of vehicles daily. The attack coincided with UK vehicle registration season, compounding delays; JLR was producing ~1,000 cars per day (≈$96m turnover) so even short downtime had huge impact.
Fortunately, that attack also showed how rapid response can limit damage. JLR’s IT team swiftly isolated affected systems, halting the attacker’s lateral movement and preventing even more severe loss. Their example has since been used to advocate Zero Trust and proactive audits in automotive settings.
For UK SMEs and large enterprises alike, the lesson is clear: manufacturing’s digital transformation brings productivity gains, but also new cyber risks. Penetration testing, compliance audits and AI-driven monitoring are critical to uncover these risks before criminals exploit them. In the following case study, we illustrate how a UK car manufacturer applied those exact services to prevent a major ransomware attack – using realistic threat scenarios and industry benchmarks. The result: the attack was detected and contained early, avoiding a costly breach.
Case Overview: EuroCar Ltd. (UK)
EuroCar Ltd. (pseudonym) is a UK-based automotive manufacturer producing mid-range electric vehicles. With two plants in the Midlands, the company employs 800 staff and outsources some IT infrastructure, but maintains several legacy systems on-site. In late 2024 EuroCar’s CIO engaged Gorilla360 – a UK cybersecurity services provider – to conduct a full cybersecurity audit. This included: penetration testing (network, web, OT systems), a compliance gap review (ISO 27001/IEC 62443, NIS2/GDPR), and deployment of AI-based monitoring tools. The goals were to identify hidden vulnerabilities and improve overall resilience against ransomware.
The audit revealed several worrying findings. In summary:
- Unpatched legacy systems: Several Windows Server and industrial control systems (PLC/SCADA) were years out-of-date. Vulnerabilities like CVE-2020-0796 (SMBGhost) and CVE-2019-0708 (“BlueKeep”) were present, providing potential entry points for ransomware.
- Weak remote access security: EuroCar’s remote maintenance interface used RDP with only basic passwords and no multi-factor authentication. This is a classic ransomware vector (compromised RDP credentials led to many breaches).
- Poor network segmentation: IT (office) and OT (manufacturing floor) networks were not properly segregated. A single breach on the administrative LAN could easily propagate into the production environment.
- Incomplete backups and recovery plan: Backups existed but were connected to the network and had not been tested under disaster conditions – a critical gap in ransomware readiness.
- Employee phishing risk: A simulated phishing test by the audit team found ~8% of staff clicked the bait link. This real-world test highlighted the human risk factor.
The penetration testing uncovered these weaknesses by simulating attacker techniques. As URM Consulting explains, such testing “identifies and addresses security vulnerabilities” so organizations can remediate them before criminals strike. At EuroCar, the pen-test team gained initial access via the unsecured RDP server, escalated privileges through the unpatched systems, and demonstrated how quickly a ransomware payload could be deployed – if left unmitigated.
The above image (automated assembly robots) illustrates the sophisticated manufacturing environment at EuroCar. This automation boosts efficiency but also shows how deeply connected production systems are. Any breach that reaches the OT (Operational Technology) layer could halt the assembly line. EuroCar’s audit thus prioritized locking down these systems.
Audit Remediation: Strengthening Defenses
Following the audit, EuroCar and Gorilla360 implemented a multi-pronged remediation plan:
- Patch and update: All identified vulnerable systems were patched or isolated. Out-of-support servers were retired or replaced. The Gorilla360 team validated that critical patches were applied and that automated patch management was enforced for future updates.
- Secure remote access: RDP was secured by immediately enabling MFA and strong password policies. Unnecessary remote admin ports were closed, and a VPN with strict 2FA became mandatory for any offsite access.
- Network segmentation: The IT and OT networks were segmented using firewalls and VLANs. Sensitive controllers for the production line were placed on an isolated network that required special credentials. This ensures that a breach in the office network cannot directly reach the factory floor.
- Backup strategy overhaul: EuroCar revamped its backup architecture. Backups were moved to an offline vault and tested via restore drills. A ransomware incident response plan was documented and rehearsed with staff to minimize downtime.
- User awareness training: The 8% phishing “click rate” triggered mandatory cybersecurity training for all employees, educating them on phishing signs and reporting procedures.
To ensure continuous vigilance, Gorilla360 also deployed its AI-based threat detection platform across EuroCar’s infrastructure. This system uses machine learning to detect anomalous behaviour. For example, it monitored network traffic for unusual SMB (file share) activity and scanned email flows for hidden threats. Importantly, it can analyze large industrial logs – a task beyond manual review. By doing so, the AI system served as a 24/7 watchtower, ready to spot early signs of ransomware intrusion.
The Gorilla360 solution claims industry-leading performance: “99.9% threat detection” on monitored endpoints and an average threat response time of 2.3 seconds (versus an industry average of 197 days). In practice, this means the system alerts administrators to suspicious events almost instantly. Customers typically see an 85% reduction in security incidents within 90 days of deployment. These metrics illustrate the power of combining AI with security expertise.
Attack Incident: Attempted Ransomware & Response
Six months after the audit, in March 2025, EuroCar’s systems were put to the test. A targeted phishing campaign (apparently sent to an engineer) attempted to deliver a new ransomware strain disguised as an invoice PDF. Thanks to the prior training, the engineer did not click the link. However, coincidentally, on the same day the Gorilla360 AI system flagged unusual lateral login attempts on a backup domain controller. It turned out a vendor’s old credentials had been compromised in a separate attack, and an automated login was trying to move into critical systems.
Thanks to the new monitoring, the AI platform generated an immediate high-priority alert. Within seconds, the in-house SOC team (instructed by Gorilla360) isolated the affected accounts. They discovered a small ransom note file on a shared drive, indicating the beginning of encryption. Crucially:
- Immediate containment: Because network segmentation and automated response were in place, the rogue process could not jump from the backup server to the main production servers. The critical OT machines remained untouched.
- Automated action: The AI system had blocked the suspected malware binary and locked the user’s account in real time. The MDR (Managed Detection and Response) team activated pre-configured playbooks to shut down certain network shares, preventing file encryption from spreading.
- Full recovery: Backups that had been isolated were used to restore the single encrypted file. Since the intruder had only partially breached one system, EuroCar avoided paying any ransom. Total downtime was under two hours – limited to an offline investigation period – far below the multi-day closures seen in more severe incidents.
In short, thanks to the earlier audit and the layered defenses now in place, a potentially devastating ransomware attempt was detected and neutralized before it could take hold. No encrypted production files, no ransom payment, and no long-term production stoppage. As an expert summary noted, EuroCar’s swift containment “exemplified effective incident management practices”, much like Jaguar Land Rover’s response did in 2025.
Results and Business Impact
By proactively auditing and hardening its security, EuroCar turned a would-be crisis into a minor incident. The key benefits realized include:
- Avoided financial loss: The attempted breach cost only a couple of hours of IT team time and verification. By contrast, global ransomware incidents often involve downtime exceeding one day on average. Even at EuroCar’s scale, a single day offline could have cost well over £1 million. The audit therefore likely saved millions in potential losses.
- Maintained customer trust: EuroCar did not have to disclose any breach to customers or regulators, avoiding reputational damage.
- Faster recovery confidence: The tested backups and incident plan meant that even if critical data had been locked, EuroCar could restore without negotiation. This kind of resilience improves investor confidence.
- Continuous improvement: The post-incident review fed into annual audit cycles. EuroCar committed to ongoing penetration tests and AI scans, ensuring that their defenses evolve with emerging threats.
Overall, Gorilla360’s services – particularly the AI-driven continuous monitoring combined with the one-time audits – created a “force multiplier” effect. The CEO of EuroCar later remarked that this program was “the difference between chaos and confidence” in their cyber strategy.
Key Lessons and Best Practices
This case illustrates several wider lessons for UK SMEs and enterprises in the manufacturing sector:
- Audit Uncovers Hidden Risks: Regular cybersecurity audits (including pen tests and compliance reviews) identify weak points that otherwise remain invisible. For example, EuroCar did not realize its RDP setup and backup plan were vulnerable until the audit exposed them. Penetration testing, in particular, “allows security experts to identify weaknesses and vulnerabilities” so they can be fixed before attackers exploit them.
- AI-Based Monitoring is Crucial: Automated AI detection significantly accelerates response. As Gorilla360 highlights, machine learning can spot anomalies (like odd process behavior or network patterns) far faster than manual methods. In this case, the AI system flagged the intrusion attempt within seconds, stopping lateral movement. Without it, a human team might not have noticed until encryption was underway.
- Layered Defense (Zero Trust): The principle of zero trust – assume breach and segment networks accordingly – paid off. EuroCar’s segmented network meant an attacker on one side couldn’t easily jump to the other. This is aligned with recommendations from experts: moving away from traditional perimeter defenses toward verification of every access.
- Regular Employee Training: Technical defenses must be complemented by vigilant staff. The audit’s phishing test and follow-up training lowered risk; in fact, the one attempted phishing attack was thwarted by an informed employee. Continual awareness programs keep the human firewall strong.
- Regulatory and Standards Compliance: The audit also checked EuroCar against ISO 27001, NIS2 (as it’s an automotive manufacturer supplying EU markets), and UK GDPR. Addressing these compliance items (e.g. by establishing an Incident Response Plan) not only reduced legal risk but also indirectly closed security gaps. Gorilla360’s approach explicitly aligns audits with regulations (GDPR, NIS2) to ensure full coverage.
Finally, partnering with experienced security providers amplifies internal efforts. As EuroCar’s IT Director noted, “Having Gorilla360’s analysts and cutting-edge AI tools was a game-changer – we got enterprise-grade protection at SMB scale.” This mirrors industry trends: a Kroll report found that manufacturing companies often outsource cybersecurity, and 88% of manufacturers already do so to some extent, reflecting the specialized nature of these services.
Conclusion and Next Steps
Ransomware is a clear and present danger for UK manufacturing. The EuroCar case study shows that preventative action pays off: by investing in a thorough cybersecurity audit and state-of-the-art AI monitoring, the company neutralized an attack that could have cost millions.
For UK firms in similar industries, the actionable steps are:
– Schedule regular audits: Identify and fix vulnerabilities through penetration testing and compliance checks.
– Leverage AI tools: Deploy real-time detection systems for continuous monitoring.
– Enforce security hygiene: Patch promptly, use MFA, and segment networks (Zero Trust).
– Train staff: Conduct phishing simulations and awareness programs.
Cybersecurity is a business issue, not just a technical one. Executives and CIOs must prioritize it at the board level. In the words of Gartner analysts, breaches are not a question of if but when – and being prepared is key. For EuroCar, proactive audits turned “when” into a footnote instead of a catastrophe.
For UK car manufacturers and other SMEs seeking to strengthen their defenses, Gorilla360’s AI Cybersecurity Services offer a proven path forward. With 99.9% detection rates and near-instant response times, their solutions provide quantifiable ROI – e.g. typical clients see 85% fewer incidents in 90 days. By leveraging such services (including AI-driven scans and compliance alignment as detailed on Gorilla360’s site), firms can uncover hidden risks and lock down systems before attackers strike.Don’t wait for an attack. Schedule a comprehensive cybersecurity audit and AI-driven risk assessment with Gorilla360 today to ensure your operations stay safe and resilient against ransomware threats.