Technological advancements have helped improve forklifts and other materials handling equipment, resulting in models that work autonomously or include connectivity features. 

However, these enhancements also create the potential for cyberattacks. How can decision-makers prevent online intruders aiming to halt operations and leak sensitive information?

Identify and reinforce attack points

Stronger cybersecurity starts when leaders recognise what intruders may target. For example, connected forklifts usually connect to Wi-Fi or 5G networks and communicate with centralised systems to broadcast their real-time position and task status to authorised users. 

These assets also have path-planning features, lidar scanners and other technologies that allow them to navigate safely through busy warehouses. 

Some of the newest offerings contain built-in, high-performance computing hardware for processing data from assorted cameras and sensors, ensuring continual environmental awareness. These components help materials handling machines perform reliably in demanding environments. However, they may also serve as opportunities for motivated hackers to exploit. 

Hiring an external security consultant familiar with connected materials handling products and the associated attack strategies is an excellent safeguard against future issues. The professional can conduct a detailed audit to find weaknesses and recommend how to address them. 

Develop emergency response plans

Responsible industrial professionals create detailed frameworks that describe the necessary responses following power outages, natural disasters, theft or other adverse events. They should do the same to anticipate cyber threats. 

Robust security measures can protect against internet security vulnerabilities, stopping them from affecting entire networks and companies. A proactive posture assigns individuals the task of alerting relevant authorities —including police and data regulators — when applicable. It also prevents panic and confusion. 

In June 2024, Crown Equipment experienced a cyberattack linked to an international criminal organisation. It required a temporary operating system shutdown and halted production. Representatives noted that the company’s ongoing cybersecurity measures limited the damage. 

Business leaders also collaborated with computing experts and law enforcement personnel to determine the next steps. This case is a strong example of how forethought can minimise the aftermath, ultimately raising the confidence of current and potential customers. 

Prioritise employee education

Materials handling equipment investments require decision-makers to train workers in basic operating procedures, support them in earning relevant certifications and clarify the correct steps for documenting accidents or abnormalities. 

Treating these efforts as continual necessities instead of one-off tasks cultivates a strong safety culture that emphasises personal accountability and looking out for fellow team members. 

Many newer forklift models include safety-oriented tools. For instance, active operator-assist features like audible and visual hazard alerts and automatic braking increase situational awareness and reinforce desired behaviours. In the same way, cybersecurity is essential to keeping warehouses safe.

Safety training should contain cybersecurity modules on how everyone contributes to online threat prevention. Simple but impactful decisions — such as setting hard-to-guess passwords and reporting phishing attempts to the appropriate individuals — prevent costly and disruptive attacks and data breaches. 

Keep materials handling equipment updated 

Connected material handling equipment can boost competitiveness, elevate output and help companies address labor shortages. Decision-makers can harness these advantages by designing thorough management plans for their new assets. 

One of the easiest and most effective strategies is to install all new software and firmware when available. Some manufacturers provide apps or interfaces for authorised parties to access and schedule upgrades outside business hours for minimal disruption. Others offer automatic, over-the-air updates, ensuring customers get the latest features and patches without manual installations.

A 2024 study by NTT DATA reveals 80% of executives felt inadequate or old technologies restricted organisational progress and innovation potential. IT personnel can keep equipment investments performing optimally by staying aware of vendor-provided updates. 

These releases contain new features and plug the vulnerabilities that cybercriminals target in attempted attacks.

Take cybersecurity seriously

Connected material handling products can streamline workflows and boost output, but also elevate cyberattack risks. Proactive measures — such as reinforcing attack points, developing a response plan, investing in employee training and updating equipment — can significantly lower the threat, keeping businesses operational and efficient.