Multi factor authentication sounds simple, yet factory floors introduce quirks that catch teams off guard. Between variable connectivity and shared workstations, the gap between theory and practice widens fast.

Read along to learn the blunders to avoid and fixes to employ when push comes to shove.

1. Relying Only On SMS OTP

SMS codes seem convenient, and they actually are in many ways. But production environments often suffer from poor cellular reception. That delay creates risky fallback habits.

Short-lived tokens and app-based methods tend to give tighter control in places where network signals fluctuate.

2. Ignoring Offline Modes

Factories with heavy machinery sometimes block signals. MFA that stops working during dropouts slows technicians and frustrates operators.

Enter local backup codes or hardware tokens. They keep teams moving even when the network briefly fades during peak activity.

3. Not Pilot Testing

Rolling out MFA across busy shifts? Without a trial, the exercise can create confusion. A quick pilot catches mismatched workflows, odd kiosk behavior, or resistance from teams.

IT Leaders who understand the challenges faced  during adoption generally spot friction early enough to smooth the launch across the floor. If need be, they seek the necessary tech support.

4. Allowing Shared Passwords

Some plants still rely on shared logins for speed. MFA cannot compensate when the base identity is insecure. Individual accounts and simple assignment procedures usually keep access trails clean and reduce guesswork when something goes wrong.

5. Overlong OTP Windows

Extended OTP lifetimes make sense on paper. Yet manufacturing stations often remain unattended for moments at a time. Shorter windows, paired with stable authenticators like facial recognition, usually balance convenience with the need to limit window hopping.

●       Short windows reduce idle exploitation.

●       Fresh codes keep access clean.

6. Poor Role Separation

Maintenance teams, operators, supervisors – each interact with systems differently. Blended permissions add confusion. Insights from WebAsha Technologies on MFA vulnerabilities highlight how unclear privilege layers weaken the entire authentication chain, especially when MFA fatigue starts creeping in.

7. Clunky Kiosks

Aging kiosks often struggle with MFA prompts. Slow touchscreens or laggy browsers break authentication cycles under pressure. According to a recent TechRadar explainer, this makes fallback paths easy targets for hackers, and kiosks with outdated software accidentally create those opportunities.

8. Weak Recovery Flows

A misplaced token during a night shift can leave teams stranded. Recovery steps that rely on email only or slow processes reduce uptime.

As the 2025 Multi Factor Authentication guide from ShadeCoder points out, layered recovery channels often stop lockouts without weakening overall posture.

9. Skipping Incident Drills

Teams rarely rehearse what happens when MFA misfires. Small outages reveal gaps in communication lines and password reset awareness. This makes running lightweight drills from time to time a big win. It helps uncover breakpoints others might otherwise miss.

A couple of quick reminders often stick best on busy shop floors.

For Example:

●       Running a short drill during a quiet window often reveals whether recovery steps hold up under pressure.

●       Simple notes on what to do when a token fails or a code won’t load help crews stay calm during real disruptions.

Endnote

A solid MFA plan keeps production lines safer and teams calmer. Manufacturers that rethink daily authentication friction often gain smoother shifts and fewer panicked calls.

Want more insights like this? Explore similar topics on our blog for practical guidance without the jargon.

*** This is a Security Bloggers Network syndicated blog from MojoAuth - Advanced Authentication & Identity Solutions authored by MojoAuth - Advanced Authentication & Identity Solutions. Read the original post at: https://mojoauth.com/blog/9-mfa-mistakes-in-manufacturing-it-and-fixes