Strengthening Industrial Security Through Operational Technology (OT) Security Testing

Client Profile

A leading manufacturing company operating smart factories and industrial control systems (ICS) relied on Operational Technology (OT) infrastructure to manage production lines, supply chains, and critical industrial processes. With increasing cyber threats targeting SCADA systems, PLCs, HMIs, and industrial networks, ensuring OT security was essential to prevent disruptions, cyber-physical attacks, and compliance violations.

Challenges Faced

Before undergoing OT Security Testing, the company identified multiple security concerns:

  • Unpatched vulnerabilities in Supervisory Control and Data Acquisition (SCADA) systems and Programmable Logic Controllers (PLCs).
  • Flat network architecture, allowing unauthorized access and lateral movement between IT and OT environments.
  • Lack of network segmentation, increasing the risk of ransomware spreading across industrial systems.
  • Weak authentication mechanisms, leaving HMIs, remote access points, and engineering workstations exposed.
  • Use of outdated legacy systems, making security patching difficult.
  • Compliance concerns with NIST 800-82, ISA/IEC 62443, and NERC CIP standards.
Our Approach

To strengthen OT security, we conducted a comprehensive Operational Technology Security Testing engagement, identifying vulnerabilities and providing remediation strategies.

1. Scoping & Threat Modeling

We collaborated with the client to define:

  • Scope of testing, including SCADA, PLCs, RTUs, HMIs, DCS, and industrial IoT (IIoT) systems.
  • Threat models specific to industrial environments, such as insider threats, supply chain risks, and remote access vulnerabilities.

Testing methodologies, including Black Box, Gray Box, and White Box testing.

2. Security Testing Execution

Using industry-standard frameworks like MITRE ATT&CK for ICS, NIST 800-82, ISA/IEC 62443, and Purdue Model Security, we conducted rigorous OT security testing, covering:

  • Network Security Testing – Assessing segmentation, firewall configurations, and unauthorized access risks.
  • SCADA & PLC Penetration Testing – Identifying vulnerabilities in controllers, engineering workstations, and firmware.
  • Physical Security Assessment – Evaluating access controls to critical OT assets.
  • Remote Access & VPN Security Testing – Ensuring secure connections for industrial control system operators.
  • Protocol & Communication Security Testing – Analyzing Modbus, DNP3, OPC-UA, and proprietary industrial protocols for security weaknesses.
  • Firmware & Embedded Device Testing – Identifying backdoors, hardcoded credentials, and weak cryptographic implementations.
  • Incident Response & Threat Detection Evaluation – Assessing how well OT security teams can detect and respond to threats.
  • Supply Chain & Third-Party Risk Analysis – Evaluating security of third-party integrations and vendor-supplied software.
3. Findings & Risk Assessment

After completing the penetration test, we provided a detailed security report, including:

  • Critical, High, Medium, and Low-risk vulnerabilities, with business impact analysis
  • Proof-of-Concept (PoC) exploits, demonstrating how attackers could disrupt industrial operations.\
  • A prioritized remediation roadmap, helping the company fix vulnerabilities efficiently.
4. Remediation Support & OT Security Best Practices

To ensure OT environments remained secure, we provided:

  • Network segmentation strategies, ensuring separation between IT and OT networks.
  • SCADA and PLC hardening techniques, preventing unauthorized access and code execution.
  • Implementation of secure remote access controls, reducing attack surfaces.
  • Patch management strategies for legacy systems, minimizing security risks.
  • Enhanced logging, monitoring, and incident response measures.
  • Re-testing of critical vulnerabilities, ensuring proper remediation.
5. Compliance & Continuous Security

After implementing security fixes, the company achieved:
A more resilient OT environment, reducing the risk of industrial cyber attacks.
Compliance readiness for NIST 800-82, ISA/IEC 62443, NERC CIP, and other OT security standards.
Improved threat detection and response capabilities.
Implementation of proactive security monitoring for continuous risk mitigation.

Results Achieved

Within six weeks, the company successfully:

  • Eliminated all critical vulnerabilities, reducing the risk of cyber-physical attacks.
  • Strengthened SCADA and PLC security, ensuring safe industrial operations.
  • Hardened network architecture, preventing unauthorized access and lateral movement.
  • Adopted a proactive OT security strategy, enhancing overall resilience.
Conclusion

By leveraging our OT Security Testing expertise, we helped the manufacturing company proactively identify vulnerabilities, strengthen industrial control system security, and ensure compliance with industry regulations. Our structured approach, from threat modeling to remediation, ensured the OT environment remained resilient against cyber and physical threats.

Need OT Security Testing?

If you’re looking to secure your industrial control systems, SCADA environments, and OT infrastructure, reach out to us today for a customized OT security assessment.

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.

 

Take Control of Your Cybersecurity Future

Don’t wait for a data breach to happen. Contact COE Security LLC today for a consultation and take control of your cybersecurity future.