The Manufacturing IT "Health Score" Tool

Manufacturing IT is fundamentally different from office IT. While a law firm experiences a slow email server as an inconvenience, a manufacturer experiences a network outage as a production stoppage—with costs measured in thousands of dollars per hour of lost output.

The Five Dimensions of Manufacturing IT Health

The Core12 Manufacturing IT Health Score evaluates your plant-floor infrastructure across five critical dimensions, each scored on a 20-point scale for a total possible score of 100.

Dimension 1: Network Resilience (20 points)

Network resilience measures your ability to maintain connectivity during ISP outages, equipment failures, and traffic surges. Key assessment factors include:

• Redundant WAN connectivity: Do you have multiple ISP connections with automatic failover? Manufacturers running on a single ISP circuit face catastrophic risk—a single fiber cut can halt production entirely.
• SD-WAN implementation: Is your network intelligent enough to route production traffic through the best available path automatically? Application-aware routing ensures that ERP, MES, and EDI traffic receives priority over general internet usage.
• Internal network redundancy: Do your core switches have redundant power supplies and stacking configurations? A single switch failure in a flat network can take down an entire production floor.

Dimension 2: OT/IT Segmentation (20 points)

OT/IT segmentation evaluates the separation between your production operational technology networks and corporate IT networks:

• Network segmentation: Are PLCs, HMIs, and SCADA systems on isolated VLANs with controlled access from the corporate network? Flat networks where an accountant's laptop shares a broadcast domain with CNC controllers represent a critical security failure.
• Industrial DMZ: Is there a demilitarized zone between IT and OT networks with protocol-aware firewalls? This DMZ should inspect traffic crossing the IT/OT boundary while preventing unauthorized access in either direction.
• Access controls: Are connections from corporate IT to production systems authenticated and logged? Maintenance technicians should access production equipment through controlled jump servers, not direct RDP connections.

Dimension 3: Backup and Recovery Readiness (20 points)

Backup readiness assesses your ability to recover from data loss, ransomware, or catastrophic equipment failure:

• Backup scope: Are all critical systems backed up—including ERP databases, CNC programs, PLC configurations, and quality inspection data? Many manufacturers back up office systems but neglect production-critical data.
• Recovery testing: Do you test backup restoration regularly? A backup that has never been tested is not a backup—it is a hope. Core12 recommends quarterly restoration testing for production-critical systems.
• Recovery time objectives: Can you articulate how long recovery would take for each critical system? If your ERP goes down, do you know whether recovery takes 30 minutes or 30 hours?

Dimension 4: IoT and Sensor Security (20 points)

IoT security evaluates the protection of connected sensors, environmental monitors, and smart devices:

• Device inventory: Do you know how many IoT devices are on your network? Many manufacturers discover dozens of unmanaged sensors, cameras, and environmental monitors during security assessments.
• Network isolation: Are IoT devices on dedicated VLANs with restricted communication paths? A compromised temperature sensor should not be able to reach your ERP database.
• Firmware management: Are IoT device firmware versions tracked and updated? Unpatched IoT devices are among the most common entry points for lateral network attacks.

Dimension 5: JIT System Uptime (20 points)

JIT uptime evaluates the availability and reliability of systems supporting Just-in-Time production:

• ERP availability: What is your ERP system uptime over the past 12 months? For JIT manufacturers, even 99.9% uptime means 8.7 hours of annual downtime—potentially catastrophic during peak production.
• EDI reliability: Do your electronic data interchange systems process transactions without manual intervention? EDI failures create order processing delays that cascade through the supply chain.
• Real-time monitoring: Do you have 24/7 monitoring with automated alerting for production-critical systems? Discovering a system failure Monday morning that occurred Friday night means 48+ hours of lost production data.

Interpreting Your Score

A (90-100): Your manufacturing IT infrastructure demonstrates enterprise-grade resilience, security, and monitoring. You are well-positioned for compliance audits and supply chain partner requirements.

B (75-89): Strong foundation with targeted improvement opportunities. Common "B" gaps include incomplete IoT inventories or infrequent backup testing.

C (60-74): Basic operational capability with significant security gaps. Most "C" organizations have flat networks, limited monitoring, and untested backup procedures.

D (40-59): Serious infrastructure deficiencies that create production risk. Immediate attention required for network segmentation and backup implementation.

F (Below 40): Critical infrastructure gaps that likely violate compliance requirements and create unacceptable production risk.

From Score to Action

Your Health Score is a diagnostic tool—identifying where you stand today. The next step is translating that score into a prioritized improvement plan that addresses the highest-risk gaps first.

Core12 offers a complimentary IT Health Review for manufacturers who complete this assessment. During this session, we analyze your score across all five dimensions and create a 90-day improvement roadmap tailored to your production environment.

Core12: Your Strategic Partner for Managed IT & Cybersecurity.