Securing IoT Devices Through Penetration Testing for a Smart Manufacturing Company

Client Profile

A leading smart manufacturing company leveraging Internet of Things (IoT) devices for real-time monitoring and automation needed to ensure its IoT ecosystem was secure. Their infrastructure included connected sensors, industrial control systems (ICS), and cloud-based analytics platforms, all of which required robust cybersecurity measures to prevent cyber threats.

Challenges Faced

Before undergoing IoT Penetration Testing, the company faced multiple security concerns:

  • Weak authentication and encryption in IoT devices, increasing the risk of unauthorized access.
  • Vulnerabilities in IoT communication protocols (MQTT, CoAP, BLE, Zigbee, and LoRaWAN) that could expose sensitive industrial data.
  • Unpatched firmware and insecure updates, making devices susceptible to exploits and botnet attacks.
  • Lack of network segmentation, allowing lateral movement in case of a breach.
  • Compliance challenges with NIST IoT Cybersecurity Framework, IEC 62443, and GDPR.
Our Approach

To secure the company’s IoT infrastructure, we conducted a comprehensive IoT Penetration Testing engagement, identifying vulnerabilities and providing remediation strategies.

Scoping & Threat Modeling

We collaborated with the client to:

  • Define the scope of testing, including IoT devices, cloud integrations, APIs, and mobile apps.
  • Identify threat models specific to industrial IoT environments, such as denial-of-service (DoS), man-in-the-middle (MITM) attacks, and firmware manipulation.
  • Determine testing methodologies (Black Box, Gray Box, and White Box testing).
Security Testing Execution

Using industry-standard frameworks like OWASP IoT Top 10, NIST 800-183, and MITRE ATT&CK for ICS, we performed an in-depth IoT penetration test, covering:

  • Firmware & Hardware Security Testing – Reverse engineering firmware to identify hardcoded credentials, insecure update mechanisms, and backdoors.
  • Device Authentication & Access Control Testing – Assessing default passwords, weak authentication mechanisms, and improper session handling.
  • IoT Communication Protocol Security – Analyzing vulnerabilities in MQTT, CoAP, Zigbee, and BLE to detect data interception and unauthorized access risks.
  • API & Cloud Integration Testing – Testing for broken authentication, insecure direct object references (IDOR), and data exposure in cloud-connected IoT systems.
  • Network Security Testing – Evaluating network segmentation, firewall rules, and exposure of open ports in IoT infrastructure.
  • Denial-of-Service (DoS) Attack Simulation – Testing device resilience against high-traffic floods and resource exhaustion attacks.
  • Physical Security Assessment – Checking for vulnerabilities in device tampering, USB exploits, and JTAG/UART debugging interfaces.
Findings & Risk Assessment

After testing, we provided a comprehensive security report, detailing:

  • Critical, High, Medium, and Low-risk vulnerabilities, along with their business impact.
  • Proof-of-Concept (PoC) exploits, demonstrating real-world attack scenarios.
  • A prioritized remediation roadmap to guide the client in securing their IoT devices.
Remediation Support & Secure IoT Deployment

To ensure the IoT ecosystem remained secure, we provided:

  • Firmware hardening recommendations to eliminate insecure update mechanisms.
  • Best practices for secure authentication, such as certificate-based authentication and multi-factor authentication (MFA).
  • Guidance on IoT network segmentation, reducing attack surfaces and preventing lateral movement.
  • Encryption and secure communication implementation for IoT data transmission.
  • Re-testing of high-risk vulnerabilities to confirm remediation effectiveness.
Compliance & Continuous Security

After remediation, the company successfully:

  • Eliminated critical vulnerabilities, including weak authentication and insecure communication protocols.
  • Achieved compliance with NIST IoT Cybersecurity Framework, IEC 62443, and GDPR.
  • Implemented a secure IoT deployment strategy, minimizing risks from unauthorized access.
  • Reduced exposure to botnet attacks, such as Mirai and Mozi malware.
Results Achieved

Within eight weeks, the company successfully:

  • Secured its IoT infrastructure, ensuring safe operation of industrial control systems.
  • Hardened its IoT devices, eliminating risks of unauthorized firmware modifications.
  • Enhanced its cloud and API security, preventing sensitive data leaks.
  • Integrated security best practices into IoT device lifecycle management.
Conclusion

By leveraging our IoT Penetration Testing expertise, we helped the smart manufacturing company proactively identify vulnerabilities, enhance security controls, and achieve compliance with industry regulations. Our structured approach, from threat modeling to remediation, ensured the company’s connected devices remained secure against evolving cyber threats.

Need IoT Penetration Testing?

If you’re looking to secure your IoT devices, cloud integrations, and industrial control systems, reach out to us today for a customized penetration testing engagement.

COE Security LLC

COE Security is a leading cybersecurity services provider, offering comprehensive solutions to address the evolving threat landscape. We have a proven track record of helping organizations of all sizes mitigate risks, strengthen defenses, and recover from cyberattacks. Our team of experienced cybersecurity professionals possesses deep expertise in the latest technologies and best practices, enabling us to deliver tailored solutions that meet your unique security needs.

We offer a wide range of services, including:
Security Services
  • Application Penetration Testing – Assessing the security of applications by simulating real-world attacks to identify vulnerabilities.
  • Mobile Application Penetration Testing – Evaluating the security of mobile applications on Android and iOS to detect potential risks.
  • Web Application Penetration Testing – Identifying and mitigating security flaws in web applications to prevent cyber threats.
  • Thick Client Penetration Testing – Testing desktop applications to uncover security gaps that could be exploited by attackers.
  • API Penetration Testing – Ensuring the security of APIs by detecting vulnerabilities that could lead to unauthorized access or data leaks.
  • Network Penetration Testing – Evaluating network infrastructure for weaknesses that hackers could exploit to gain access.
  • Hardware Penetration Testing – Identifying security flaws in hardware components that could compromise overall system security.
  • Operational Technology Security Testing – Protecting critical industrial control systems from cyber threats and potential disruptions.
  • Cloud Penetration Testing – Assessing cloud environments for vulnerabilities to ensure the security of cloud-based assets.
  • AWS Penetration Testing – Conducting security assessments for AWS environments to detect and mitigate risks.
  • GCP Penetration Testing – Evaluating security risks in Google Cloud Platform (GCP) to safeguard cloud assets and infrastructure.
  • Azure Penetration Testing – Identifying vulnerabilities in Microsoft Azure cloud environments to prevent unauthorized access.
  • Alibaba Penetration Testing – Ensuring the security of Alibaba Cloud infrastructures against evolving cyber threats.
  • AI & LLM Penetration Testing – Assessing security risks in artificial intelligence (AI) and large language model (LLM) applications.
  • Red Teaming – Simulating advanced attack scenarios to test an organization’s cyber resilience against real-world threats.
  • Social Engineering Service – Identifying human-related security weaknesses through phishing, impersonation, and other social engineering tactics.
  • Product Penetration Testing – Evaluating security vulnerabilities in software and hardware products before deployment.
  • IoT Security – Securing connected devices to prevent them from becoming entry points for attackers.
  • DevSecOps & Secure Software Development – Embedding security into the software development lifecycle.