A leading manufacturing company in India embarked on an ambitious journey to strengthen its Operational Technology (OT) cybersecurity posture. With complex industrial systems, third-party connections, and evolving cyber risks, they required a structured consulting engagement that could deliver not just compliance, but clarity, resilience, and future-readiness.

Arista Cyber partnered with the client to deliver detailed architectures, risk assessments integrated with process safety, and cybersecurity requirement specifications, and testing guidelines ensuring that cybersecurity became an integral part of their operational lifecycle.

The Story Begins

In the high-stakes environment of industrial operations, downtime is costly and vulnerabilities can be dangerous. For one of India’s leading manufacturers, the question was urgent: How do we build cybersecurity into the very fabric of our OT systems, instead of treating it as an afterthought?

The company needed not only risk assessments, but also deep visibility into system architecture, third-party connections, and data flows; the building blocks of a secure OT environment. They turned to Arista Cyber for guidance.

The Challenge

The client’s OT environment spanned diverse systems and partners, presenting three major challenges:

• Complex Ecosystem – Multiple vendors, third-party connections, and layered industrial systems made it difficult to gain a unified view.
• Evolving Risk Landscape – Threats targeting OT systems required structured, standards-based assessment methods.
• Integration into Operations – Cybersecurity requirements had to be embedded into procurement, testing, and commissioning processes.

Without a clear roadmap, the risk of blind spots and fragmented defenses was significant.

Our Approach

Arista Cyber deployed a senior OT cybersecurity consultant with over 20 years of experience, supported by a junior consultant. Together, they combined technical expertise and industry best practices to deliver a comprehensive program:

• System Architecture & Inventory
  • Developed detailed architecture diagrams capturing hardware, software, and data flows.
  • Documented inventories of assets and third-party connections to build transparency.
  • Validation of OT assets ISA secure certification
• Risk Assessment
  • Conducted detailed-level risk assessments using Cyber PHA and Cyber SL tool.
  • Benchmarked findings against the client’s OT Cyber Guidelines and international standards like IEC 62443.
  • Evaluation of risk existing mitigations
  • Recommendations for sustaining cybersecurity compliance
• Cybersecurity Requirement Specifications (CSRS)
  • Prepared a structured CSRS document to formalize requirements for secure design and operation.
• FAT, & SAT and VAPT Support
  • Reviewed Factory Acceptance Testing (FAT), and Site Acceptance Testing (SAT) and Vulnerability Assessment & Penetration Testing (VAPT) cybersecurity procedures.
  • Provided comments and recommendations to strengthen testing and commissioning phases.

Governance & Procedures

• Developed a cybersecurity program aligned with NIST CSF 2.0 and IEC/ISA 62443.
• Created policies, procedures, work instructions, and operating models for all terminals.
• Collaborated with site stakeholders to adapt templates to real-world systems and workflows.
• Ensured the “secure way of working” became part of daily practice, not just documentation.

Asset Inventory & Visibility

• Conducted on-site asset and network discovery.
• Deployed automated inventory scripts to capture detailed system information.
• Investigated vulnerabilities, across all sites within OT/ICS systems.
• Documented findings in structured templates to build transparency.

Key Deliverables

• Detailed system architecture diagrams
• Comprehensive asset inventory and dataflow mapping
• Risk assessment report with prioritized findings
• Cybersecurity Requirement Specification (CSRS) document
• Reviewed and enhanced FAT and SAT cybersecurity procedures

Results & Impact

This ongoing engagement has already delivered tangible value:

• Clarity – A unified view of assets, systems, and dataflows across the OT environment.
• Risk Visibility – Structured identification of vulnerabilities and prioritized treatment options.
• Standards Alignment – Compliance pathways aligned with IEC 62443 and client OT Cyber Guidelines.
• Integration – Cybersecurity embedded into the lifecycle through CSRS, FAT, and SAT.
• Resilience Roadmap – A foundation to continuously improve defenses as threats evolve.

For this leading Indian manufacturer, cybersecurity is no longer an afterthought—it is a core part of operations. By combining architecture transparency, risk assessment, and lifecycle integration, Arista Cyber is helping them build resilient, secure, and future-ready industrial systems.