Business Continuity Plan

(BCP)
Ensuring Operational Resilience for Manufacturing

Sapiens AI Team
Executive Summary & Objectives

lan Continuous Operations & Rapid Recovery

Outlines procedures to ensure stability during disruptions. A robust
BCP allows the organization to withstand crises and resume
operations smoothly.

apps Comprehensive Scope

Covers all critical business functions including manufacturing, office
operations, IT infrastructure, production facilities, warehouses, and
delivery services.

Manufacturing IT & Data

health_and_safety Ensure Safety of Employees & Assets

Prioritizes the well-being of personnel and protects physical assets
and critical data, building trust with stakeholders.

timer Minimize Downtime

Aims to reduce operational disruptions and resume critical functions
within targeted timeframes, preserving revenue and reputation.

data_saver_on Protect Data & Supply Chain

Safeguards intellectual property through robust data recovery plans
and maintains supply chain integrity with proactive strategies. Warehouse & Logistics Data Protection

Source: JPMorgan, Arcserve, IBM, Cohesity, InvenioIT, Splunk, UNDRR, Cisco, Bryghtpath, Ncontracts
 Scope of the BCP

business_center Administrative/Office
• Ensuring continuity of essential
computer IT Systems & Server
Room
• Strategies for data protection, cloud
precision_manufacturing Production/Machineries
• Preventive maintenance and rapid
administrative tasks and communication. repair/replacement protocols.
backups, and system restoration.
• Maintaining access to critical documents, • Maintaining production via backup
• Restoring critical IT infrastructure and
financial, and HR systems. equipment or outsourcing.
applications post-disruption.
• Focus on remote work and alternate • Addressing threats like utility outages
• Includes ransomware recovery and
office locations. and physical damage.
network connectivity.

warehouse Warehouse/Inventory
• Ensuring integrity and accessibility of
local_shipping Logistics & Delivery
• Maintaining distribution channels and
inventory data and stock. timely delivery.

• Strategies for alternative storage and • Diversifying transport and identifying

system backups. alternative routes.
• Mitigating impacts from physical damage • Ensuring clear communication with
to facilities. suppliers and customers.

Key BCP Statistics

Ransomware has cost the manufacturing sector $17 billion in

downtime from 2018 to 2024.
"A failure to maintain business continuity in manufacturing can be disastrous." - InvenioIT

Source: 2005 Manufacturing Bcp.pdf

 Risk Assessment & Business Impact Analysis (BIA)

Identifies Potential Threats Conceptual Threat Impact Matrix

This process systematically identifies potential threats that could Threat Type Minor Significant Catastrophic
impact operational continuity. It involves analyzing vulnerabilities to Disruption Downtime Failure
develop targeted mitigation strategies. Based on "2005
Manufacturing Bcp.pdf", key threats include: Natural X X

Natural Disasters: Fire, Flooding, Severe Weather

Cyber X X X
Technological Mishaps: Power Outage, Cyber Attack, Equipment
Failure Operational X X

Operational Disruptions: Supplier Failure, Pandemic, Vehicle

Infrastructure X X
Accident

Source: InvenioIT, Cohesity

Evaluates Likelihood & Impact (BIA)

A Business Impact Analysis (BIA) identifies mission-essential
functions and the consequences of their disruption. It assesses the
likelihood of each threat and its potential impact (financial,
reputational, operational), forming the basis for prioritizing resources
and developing effective continuity plans.

Source: Bryghtpath

Proactive Planning Benefits

Risk Mitigation Minimized Downtime Enhanced Resilience Customer Trust

"Anticipating a potential disaster, and knowing how to adequately respond, is the best thing a company can do to avert a prolonged disruption..." -
InvenioIT

Source: 2005 Manufacturing Bcp.pdf

 Critical Functions & Recovery Objectives

shopping_cart Order Processing

Ensures continuous intake and
factory Manufacturing
Maintaining production lines and
management of customer orders. assembly processes.

RTO: < 4 hours | RPO: < 1 RTO: < 8 hours | RPO: < 2
hour hours Defining Recovery Objectives

dns
Recovery Time Objective (RTO)
IT/Server Systems
Restoration of critical IT
account_balance Accounting &
Payroll
Ensuring financial transactions and
The maximum tolerable downtime for a system or function
after a disruption. It defines the target time for restoration.

Recovery Point Objective (RPO)

infrastructure, networks, and
applications. employee compensation continuity. The maximum acceptable amount of data loss, measured in
time. It defines the point to which data must be recovered.
RTO: < 2 hours | RPO: < 30 RTO: < 24 hours | RPO: < 4
mins hours Last Backup Disruption Operations Restored

RPO (Data Loss) RTO (Downtime)

local_shipping Delivery
Operations
Maintaining logistics and product
inventory_2 Inventory
Management
Tracking and managing raw materials
Source: Disaster Recovery Plans vs. Business Continuity Plans: A Guide
- Cohesity

distribution to customers. and finished goods.

RTO: < 12 hours | RPO: < 6 RTO: < 6 hours | RPO: < 1
hours hour

Why Define RTO & RPO?

Minimizes Downtime Reduces Data Loss Prioritizes Recovery Ensures Compliance

"The restoration process follows pre-defined Recovery Point Objectives (RPO) and Recovery Time Objectives (RTO), prioritizing critical systems to minimize operation." -
Cohesity
 Business Continuity Strategies

business Office Operations

Cloud Storage: Secure and accessible
cloud IT Infrastructure
devices Office Equipment
Spare Devices: Availability of backup
data storage for all critical documents. laptops and peripherals.
Remote Work: Established Endpoint Protection: Robust
infrastructure for effective off-site work. cybersecurity on all end-user devices.
Emergency Communication: Clear
protocols for internal and external Cloud Backups: Regular, off-site
messaging. backups of critical systems and data.

UPS: Uninterruptible Power Supply for

critical hardware.
Fire Suppression: Automated systems
in data centers.

Source: Essential Guide to Business Continuity for Source: Disaster Recovery Plans vs. Business Source: Business Continuity Plan (BCP): What is it &
Operations - Bryghtpath Continuity Plans - Cohesity How Does it Work? - JPMorgan

precision_manufacturing Production
warehouse Warehouse & Inventory
local_shipping Logistics
GPS Tracking: Real-time monitoring of
shipments for rapid response.

Third-Party Options: Pre-arranged

agreements with alternative providers.

Preventive Maintenance: Regular ERP Backup: Regular backups of

servicing to minimize breakdowns. inventory management systems.
Backup Machines: Redundant Alternative Storage: Secondary
equipment to maintain output. locations for materials and goods.

Source: Manufacturing Business Continuity Plan Source: Manufacturing Business Continuity Plan Source: Essential Guide to Business Continuity for
Example - InvenioIT Example - InvenioIT Operations - Bryghtpath

Integrated Resilience
"Proper integration of these plans provides comprehensive protection against disruptions. It ensures that organizations can develop effective
strategies to address immediate technical recovery needs and sustain long-term operational continuity." - Cohesity

Proactive Planning Cross-Functional Collaboration Continuous Improvement

 Communication Plan & Roles
Communication Plan Key Roles & Responsibilities

Internal Communication
Ensuring timely information flow within the organization.
manage_accounts
BCP Coordinator
computer
IT Manager

sms SMS Alerts: Rapid dissemination of critical updates. Oversees BCP implementation Manages IT disaster recovery,

forum
and acts as the central contact data backup, and infrastructure
Messaging Real-time team coordination on during a disruption. continuity.
Apps: dedicated channels.

account_tree Emergency Hierarchical structure to ensure all

Tree: personnel are contacted.

External Communication
factory
Operations Head
local_shipping
Logistics Supervisor
Maintaining transparency with stakeholders. Manages continuity of Ensures supply chain continuity,

email Email &

SMS:
Formal updates and urgent notifications for
partners and clients.
production and coordinates
departmental responses.
manages inventory, and
oversees transport.

public Website: Centralized hub for public announcements

and status updates.

campaign Designated
Spokesperson:
Ensures consistent messaging for all
external communications.
people
HR Manager
security
Safety Officer
Manages employee welfare, Ensures personnel safety,
internal communication, and coordinates evacuations, and
staffing needs. manages on-site response.

Source: 2005 Manufacturing Bcp.pdf

data_saver_on Backup & Data Recovery Plan
Ensuring Data Redundancy and
Accessibility

cloud_sync Nightly Cloud and Local Backups

Critical data is backed up daily to both secure cloud storage
and on-premise devices.
This hybrid approach ensures redundancy and provides faster
recovery options.
"Backups stored locally and in the cloud to create redundancy in case on-
premise infrastructure is destroyed."

update Weekly Full Backups

Comprehensive full system backups are performed weekly to
capture all data and configurations.
Provides a stable recovery point for major system restorations.
"The ability to perform backups more often... so that data loss is minimized
when you need to roll back to the last recovery point."

Protecting and Validating

Recoverability
enhanced_encryption Encrypted Offsite Copies
All offsite backup copies are encrypted to protect sensitive data
from unauthorized access, ensuring confidentiality.

published_with_changes Quarterly Recovery Testing

Regular, simulated recovery exercises are conducted quarterly
to validate backup integrity and recovery procedures.
"Proactively testing and maintaining your business continuity plan ensures it
remains a reliable tool for navigating operational disruptions."

Importance of Data Protection

Minimizes Data Loss Ensures Business Continuity Protects Against Cyber Threats "Without proper planning... producers leave their companies
at risk of a catastrophic break in continuity."
Maintains Trust

Source: 2005 Manufacturing Bcp.pdf, InvenioIT, Arcserve, Cohesity

 Alternate Site Plans

apartment Office Operations

Ensuring continued administrative and
factory Production
Maintaining manufacturing capabilities
cloud_queue IT Infrastructure
Ensuring continuous IT system
support functions. and output. availability and data access.

Coworking Spaces: Pre- Third-Party Facilities: Cloud DR Site: Cloud-based

arranged agreements for temporary Agreements with external failover for critical applications and
office space. manufacturers. data.

Branch Office: Leveraging Temporary Facilities: Leasing Secondary Data Center:

existing branch offices as temporary and setting up temporary Activation of a separate, redundant
hubs. production sites. data center.

Remote Work: Full activation of Redundant Lines: Utilizing VDI Access: Remote access to
work-from-home capabilities. backup production lines in other virtualized desktops and
facilities. applications.

Strategic Importance of Alternate Sites

Operational Flexibility Reduced Downtime Enhanced Resilience Geographic Diversification

"Continuity facilities, sometimes called “alternate facilities”, go hand-in-hand with having a solid Continuity of Operations Plan (COOP).
Essentially, you are identifying another location to carry out those all-important business functions."

Source: Essential Guide to Business Continuity for Operations - Bryghtpath; Manufacturing Business Continuity Plan Example [2025 Guide] - InvenioIT; Disaster Recovery Plans vs.
Business Continuity Plans: A Guide - Cohesity
 Testing, Maintenance & Training
Continuous Readiness Cycle

event_repeat Bi-annual
BCP Drills
Full-scale simulation
cloud_sync Quarterly IT
Tests
Focused tests on IT
update Regular
Updates
Ongoing verification of
school Annual
Training
Comprehensive training
person_add
Mandatory BCP
Onboarding
Training

exercises conducted systems and data employee and for all employees on BCP awareness, first aid, and
twice a year, involving recovery every three stakeholder contacts. protocols, plus safety training for all
multiple departments to months to ensure Continuous review of department-specific new hires to foster a
test the entire BCP backup integrity and supplier details to drills to practice relevant culture of preparedness
framework and validate restoration efficiency for ensure supply chain response procedures from day one and
response procedures. critical applications. resilience and effective and improve response ensure employee safety.
communication. times.
Source: Cohesity Source: Arcserve Source: Ncontracts Source: Cohesity Source: Splunk

The Cycle of Readiness

Continuous Improvement Enhanced Preparedness Regulatory Compliance Organizational Resilience

"Proactively testing and maintaining your business continuity plan ensures it remains a reliable tool for navigating operational disruptions." -
Arcserve
 BCP Process by Threat
Specific procedures and protocols for identified business continuity threats.

local_fire_department Fire

Evacuate immediately and

power_off Power Outage

Activate UPS and backup

security Cyber Attack

Disconnect infected systems

storm Natural Disaster

Monitor alerts and evacuate

trigger alarms. generators. and isolate network. if needed.
Use fire extinguishers; call Pause production if Alert IT team immediately. Shut down systems and
emergency services. necessary. Restore systems from clean secure assets.
Account for personnel and Continue office ops on backups. Use alternate site or remote
assess damage. laptops. Notify stakeholders and work.
Switch to alternate site or If prolonged, activate review policies. Assess damage and begin
remote work. alternate site. cleanup.

build Equipment Failure

Report and isolate faulty

medical_services Health Emergency

Implement health checks and

local_shipping Vehicle Accident

Report incident and provide

handshake Supplier Failure

Identify and engage alternate

equipment. protocols. assistance. sources.
Initiate backup or outsource Remote work for non- Dispatch alternative vehicle. Use buffer inventory to
production. essential staff. Notify clients of any delay. maintain production.
Schedule emergency repair. Skeletal workforce onsite. Begin insurance claim and Notify production and clients
Review cause and update Communicate regularly with evaluate issue. of status.
maintenance. staff. Review contracts and
sourcing strategies.

Threat Landscape Overview

"Every manufacturing company—and indeed all organizations, regardless of industry—should
have both a BCP and a DRP to ensure the organization is prepared for every possible
disaster."
- InvenioIT

Source: 2005 Manufacturing Bcp.pdf

 Plan Review & Approval
Regular Review Schedule Approval by Key Stakeholders
Ensuring Plan Relevance and Effectiveness

Annual Comprehensive Review

corporate_fare
COO
person
CEO
Approves operational aspects, Provides final executive approval,
The entire BCP undergoes a thorough review annually, assessing
ensuring alignment with business signifying top-level commitment.
changes in business operations, technology, personnel, and the processes.
external threat landscape.

Quarterly Updates
Key sections like contact lists, supplier information, and IT recovery
computer
IT Head
security
Safety Officer
procedures are reviewed and updated quarterly to ensure critical Approves technical and data Approves safety protocols and
recovery components for system emergency response procedures.
details remain current.
resilience.

Post-Incident Review
Following any significant disruption, a detailed review is conducted.
Lessons learned are incorporated to enhance future response
capabilities.

Source: 2005 Manufacturing Bcp.pdf Contact: [email protected]