The ‘MacGyver Project’: Why the U.S. grid is relearning analog resilience

In an era defined by rapid digitization, the electric power sector is increasingly looking to its analog past to secure its future. During the latest episode of the Cyber Focus podcast, Scott Aaronson, senior vice president at the Edison Electric Institute (EEI), discussed the industry’s development of “Supplemental Operating Strategies” (SOS) – informally known as the “MacGyver Project.”

These strategies focus on the ability to operate the electric grid without a digital overlay. Central to this approach is the preservation of physical, manual technology, such as “pistol grip handles” – mechanical switches that allow operators to physically open or close circuits at a substation. Aaronson argues that maintaining the capacity for these manual operations is a resilience strategy the country must “make sure we don’t lose.”

The necessity of this “all-hazards” resilience was recently underscored by the massive ice and snow storm that swept across the eastern U.S. on Jan. 25. While 95% of the one million customers impacted were restored within six days, some areas required a full rebuild of the physical infrastructure rather than simple restoration. Aaronson notes that while large storms can present immense physical challenges, an “intelligent adversary” in the cyber domain presents a different threat: They may attempt to obfuscate data, leading operators to doubt the sensors and control systems they rely on.

Aaronson argues that the adversary’s true target is not just a specific utility, but the sovereignty of the United States itself. Because electricity is an “apex industry” that supports water, telecommunications and transportation, a disruption in the grid creates a cascading effect across all critical infrastructure.

The conversation, hosted by Frank Cilluffo of the McCrary Institute, further explores how these security concerns intersect with a massive new surge in energy demand. After 30 years of flat growth, the grid is now facing a “hockey stick” increase in demand driven by the repatriation of manufacturing and the rise of AI. Cilluffo emphasizes that “you cannot be AI dominant … without being energy dominant.” Aaronson agreed and called for a national pivot to building new infrastructure.

Solving for this growth requires more than just digital innovation; it demands a robust physical supply chain to support the “MacGyver-style” resilience of the underlying system. From managing a supply chain with “80,000 SKUs” for transformers to coordinating national mutual assistance, the episode highlights the complexity of what Aaronson calls “one big machine”. Ultimately, the “MacGyver Project” serves as a foundational layer of this machine’s defense, ensuring that when digital systems face uncertainty, the people behind the grid still have the manual tools to keep the lights on.

Explore more Cyber Focus conversations on the policy, threats and infrastructure shaping U.S. security at https://mccraryinstitute.com/podcast/ and subscribe today in your favorite podcast app.