Manufacturing companies are under pressure like never before. Global supply chains are more fragile, workforces are more distributed, and cyber attackers are smarter and faster. At the same time, manufacturers are integrating more connected devices—everything from IoT sensors on production lines to digital twins in engineering and smart factories running AI at the edge.
It’s no longer enough to rely on traditional firewalls, VPNs, or MPLS-based networking to keep these environments secure and productive. Security and network performance need to move with the user, with the application, and with the data—wherever they are.
This is why Secure Access Service Edge (SASE) is taking center stage in manufacturing. SASE combines security and networking into a unified cloud-delivered service that connects users securely to apps, from any device or location. Done right, it can help manufacturers modernize legacy infrastructure, enable mobile and remote workforces, reduce cyber risk, and simplify operations.
But there’s a gap between recognizing the potential of SASE and executing it well. Many manufacturers are making the same costly mistakes that stall progress or create new vulnerabilities. This article outlines the 13 most common mistakes we see—and how to avoid each with practical, actionable strategies tailored to your manufacturing environment.
Mistake #1: Treating SASE Like a Product Instead of a Strategic Framework
One of the most common—and damaging—mistakes we see is when manufacturing companies treat SASE like something they can just “buy.” This mindset is especially common in capital-intensive sectors like industrial manufacturing and robotics, where tech investments are often project-based and procurement-led. A team gets the green light to “adopt SASE,” and before long, they’re comparing vendor features as if they were evaluating a piece of machinery or a one-time software upgrade.
But SASE isn’t a SKU. It’s a strategic framework that touches identity, network architecture, cloud strategy, security policy, and operational workflows. It’s as much about how your organization thinks and operates as it is about the tools you deploy. When you treat SASE as just another box to check, you miss the real opportunity—transforming how users securely connect to applications and data, whether they’re in a smart factory, a design studio, or on the road visiting a customer site.
Take a hypothetical industrial equipment manufacturer. They rolled out a standalone secure web gateway (SWG) and cloud access security broker (CASB) from one vendor, an SD-WAN solution from another, and still rely on legacy VPNs for remote access. Everything technically falls under the “SASE” umbrella, but nothing works together. The result? User complaints, policy gaps, and a growing pile of exceptions that make audits painful and risk unpredictable.
The smarter approach is to treat SASE as a business-aligned roadmap, not a one-off purchase. Start by aligning your SASE strategy with key outcomes—like reducing third-party risk, accelerating supplier onboarding, or protecting intellectual property. Build your roadmap around three pillars: converged networking and security, identity-based access, and cloud-first architecture. This way, your SASE rollout becomes a driver of transformation, not a patchwork of point solutions.
Mistake #2: Ignoring OT/IT Integration
In sectors like chemical manufacturing and pharma production, operational technology (OT) environments are mission-critical—but often operate in silos from IT. When SASE is scoped only around the IT environment, it creates blind spots that attackers can exploit. The assumption is that OT is “air-gapped” or doesn’t need the same level of policy-based access control, but this is outdated thinking. More OT systems are now connected for monitoring, analytics, or remote access, and those connections must be protected.
Consider a pharma manufacturing plant where quality control systems feed into cloud analytics dashboards. If those OT devices are not authenticated, segmented, or monitored under the same SASE policy umbrella, attackers can pivot from a compromised sensor to critical production assets. We’ve seen similar gaps in chemical facilities where remote engineers access programmable logic controllers (PLCs) without granular access rules—introducing major risk.
The fix is to bring OT into the fold with intelligent segmentation and policy enforcement. Use identity-aware controls and microsegmentation to limit lateral movement. Deploy visibility tools that can recognize OT protocols and devices—even legacy systems—and apply contextual rules that govern access based on role, device posture, and behavior. Integrating SASE into OT doesn’t mean you touch every controller; it means building secure zones and access pathways that bridge IT and OT safely and intentionally.
Mistake #3: Not Starting with Identity-Based Access
SASE isn’t IP-based security. It’s identity-based. That’s a crucial distinction, especially in industries like construction materials or CPG, where workforces are often transient, and contractors, vendors, or temporary staff may require access to sensitive apps or data. If you’re still granting access based on static IP addresses or network location, you’re giving access to whoever connects from the right place—not necessarily the right person.
Imagine a CPG company outsourcing packaging design to a third-party firm. Without identity-aware access controls, the external designer might get blanket access to internal design and production systems simply because they’re on the VPN. That’s a problem.
The better approach is to invest in strong identity foundations: integrate multi-factor authentication (MFA), use signals like device trust and location, and segment access based on user role and business need. Make sure your SASE implementation can enforce these policies in real time—whether a user is in the factory, the field, or at home.
Mistake #4: Failing to Modernize the WAN First
In high-tech or semiconductor manufacturing, where speed and scale are everything, bolting a cloud-native security model onto an MPLS-heavy WAN just doesn’t work. The result is latency, fragmented control, and escalating costs. It’s like putting a Formula 1 engine in a dump truck chassis—it won’t perform as expected.
A semiconductor firm, for example, may have facilities across APAC, North America, and Europe, all interconnected with MPLS links and traditional branch firewalls. Trying to layer SASE on top of this architecture often leads to slow application performance, especially for cloud workloads and remote developers.
The fix is to modernize your WAN with SD-WAN or cloud-delivered networking. Prioritize direct-to-cloud access for your most critical apps, and use intelligent path selection to ensure performance. This not only improves user experience but gives your security stack better visibility and control over traffic flows—key to making SASE work.
Mistake #5: Underestimating Application Discovery and Visibility
You can’t protect what you can’t see. In automotive and electronics firms, where the application portfolio can include ERP, PLM, CAD tools, customer portals, and third-party engineering platforms, it’s easy for shadow IT to proliferate. This creates blind spots for security teams and cracks in your zero trust model.
Let’s say an automotive supplier has a design team using an unsanctioned cloud-based 3D rendering tool. That traffic may never touch your managed network, and without full visibility, your SASE policies won’t apply. Worse, sensitive designs might be stored in unapproved locations.
The fix is to start every SASE journey with a full application discovery phase. Use tools that automatically inventory cloud, on-prem, and SaaS apps—whether they’re officially approved or not. From there, categorize apps by risk, ownership, and usage frequency. This gives you a baseline to build policies, enforce controls, and eliminate risky or redundant services.
Mistake #6: Assuming All SASE Vendors Are Equal
Not all vendors deliver true convergence, global scale, or deep integration—and picking the wrong one can stall your entire SASE effort. Architecture, not branding, should drive your choice. Yet, in architecture, engineering, and construction (AEC) or infrastructure firms, we’ve seen too many selections made based on bundled discounts or longstanding reseller relationships.
For instance, a construction materials company might go with a bundled solution from their firewall vendor, only to find it doesn’t offer a unified management console, or lacks POPs (points of presence) in key regions where remote teams work. The result? Complexity, poor performance, and limited visibility.
The fix is to vet SASE vendors rigorously. Look for tight integration across all core functions (SWG, CASB, ZTNA, SD-WAN), global performance SLAs, and proven experience supporting your industry’s needs. Ask vendors to demonstrate real-time policy updates, contextual access enforcement, and unified logging. Don’t accept demos—demand pilots.
Mistake #7: Rolling Out SASE Without Clear Governance
Even in the most security-conscious pharma or industrial firms, SASE rollouts can stall if there’s no clear governance. Without defined roles, policy hierarchies, and approval flows, teams end up with conflicting rules, shadow admins, or unclear escalation paths.
For example, a pharma manufacturing site might deploy access policies for R&D teams while corporate security simultaneously manages a separate set for external contractors. When the two sets overlap—or worse, conflict—it creates gaps attackers can exploit.
Start by mapping policy ownership. Who defines access rules? Who approves exceptions? How are changes audited and tracked? Make governance part of your architecture, not an afterthought. Establish clear policy tiers—global, regional, and local—and ensure each has designated owners. Use centralized policy engines and approval workflows to maintain consistency.
Mistake #8: Skipping Change Management and Training
CPG and automotive companies often have frontline employees, remote engineers, and third-party partners who aren’t IT-savvy. If they don’t understand how SASE affects their workflows—or why it matters—they’ll find ways around it. That introduces both risk and resistance.
Let’s say a regional automotive plant team starts using personal email to send design files because the new SASE rules block Dropbox. Instead of submitting a request, they work around the system—creating compliance issues.
Fix this by prioritizing change management. Communicate early and clearly: what’s changing, why it matters, and how users benefit. Tailor training to different roles—factory staff, designers, execs, contractors. Equip support teams to handle questions quickly. Treat user experience as part of your security strategy.
Mistake #9: Overlooking Legacy App Constraints
Legacy apps are everywhere in manufacturing—especially in robotics and construction materials. These apps may not support modern authentication protocols, API integration, or inline traffic inspection. Ignoring these limitations can either derail your SASE plan or force insecure workarounds.
For example, a robotics manufacturer may rely on a legacy CNC management tool that only runs over a hardcoded IP and port combination. Blocking it or forcing inspection breaks the app, but letting it through unprotected violates your zero trust principles.
The fix? Identify your legacy dependencies early and classify them based on business criticality. For high-risk, high-value apps, create secure tunnels or apply compensating controls like network segmentation and session recording. SASE doesn’t mean 100% coverage overnight—it means smart coverage now with a plan to improve over time.
Mistake #10: Not Designing for Remote and Mobile First
Manufacturing is no longer tied to the factory floor. Semiconductor engineers work from multiple design centers, high-tech support teams are globally distributed, and executives need secure access from anywhere. If your SASE strategy assumes users are always inside your network perimeter, it’s already outdated.
One high-tech electronics firm designed their SASE policies around office locations, then struggled when engineers complained about performance from home or on the road. Policies were inconsistent, access was spotty, and trust in IT declined.
Start with a user-first design. Build policies around user identity, device posture, and risk level—not physical location. Use cloud-delivered gateways with local POPs to reduce latency and improve experience. And ensure that mobile and remote access gets the same level of control, visibility, and protection as in-office traffic.
Mistake #11: Deploying SASE Without Measuring Experience
Security doesn’t matter if the network slows down or apps break. This is especially true for plant-floor systems in industrial or chemical manufacturing, where latency can impact safety or quality control. SASE done wrong can feel like a step backward if users perceive degraded performance.
A chemical manufacturer once deployed SASE to secure remote access for process engineers, only to find that real-time monitoring dashboards lagged. The issue wasn’t policy—it was poor routing and lack of monitoring.
Use Digital Experience Monitoring (DEM) tools to measure baseline performance before SASE deployment, then track user experience continuously. Validate that your policies improve both security and speed. And use those insights to fine-tune performance—not just fix complaints.
Mistake #12: Failing to Segment Roles and Risk
One-size-fits-all policies don’t cut it. In pharma or semiconductor manufacturing, exposing R&D environments to general employee traffic is a massive risk. But many firms fail to segment based on job function, sensitivity, or behavior.
Take a pharma company that allows both clinical researchers and marketing teams to access a shared storage environment. That’s not just poor policy—it’s a regulatory risk.
Apply granular segmentation. Define access based on job roles, projects, geographies, device posture, and behavioral risk. Leverage behavioral analytics to detect anomalies and adapt access dynamically. This isn’t complexity for its own sake—it’s precision that protects your most valuable assets.
Mistake #13: Waiting for “Perfect Readiness”
In AEC and infrastructure sectors, we often see firms delay SASE adoption because they feel their legacy environments are “too messy.” But waiting for perfect conditions only increases your risk exposure. You don’t need a full transformation to get started.
Instead, start with pilots. Secure third-party access to project management systems. Replace legacy VPN for remote designers or engineers. Segment access to high-value applications. Each small win builds momentum and drives ROI.
Think of a mid-sized architecture firm that started by securing access to a cloud-based BIM tool used by external contractors. Within months, they expanded to email security, then SD-WAN, and eventually a fully integrated SASE stack. You don’t need to do everything at once—but you do need to start.
Six Practical Steps for Manufacturers to Start Adopting SASE Today
- Choose the Right Single-Vendor SASE Platform: Consolidate networking and security into one provider for better integration, visibility, and performance. Avoid stitching together tools.
- Modernize the WAN with SD-WAN: Replace MPLS where possible. Use cloud-delivered networking to support direct-to-app access and reduce latency.
- Build Identity-First Access Policies: Implement MFA, contextual access rules, and device posture checks to enable zero trust from day one.
- Discover and Classify Applications: Use visibility tools to map out your app landscape—across cloud, on-prem, SaaS, and shadow IT.
- Segment Based on Risk and Role: Apply least-privilege access across users, locations, and devices. Tailor policies to job functions and behaviors.
- Start Small, Prove Value, Scale Fast: Pick one or two high-impact use cases—third-party access, remote connectivity, or app segmentation—and deliver quick wins.
Final Thoughts: What Great Manufacturing Teams Do Differently
The best manufacturing teams aren’t waiting. They’re adopting SASE iteratively and aligning each phase to business outcomes. In automotive, firms are using SASE to onboard suppliers faster without increasing risk. In CPG, leaders are securing third-party logistics platforms to protect brand integrity. High-tech firms are using SASE to streamline M&A integration—reducing complexity while increasing visibility.
SASE is more than a security play. It’s a business enabler. When you treat it as a strategic framework—guided by identity, performance, and governance—it becomes a powerful tool to support innovation, agility, and resilience across your manufacturing ecosystem. Start now. Start smart. And scale what works.