OT Vulnerability Assessment
Understand where your OT systems are exposed before issues become incidents.
Industrial facilities depend on technology that must operate reliably every day. When a vulnerability exists in a production environment, it isn't just a cybersecurity concern; it can directly affect safety, output, and operational continuity.
Many plants still have devices that were never designed to operate on modern networks. Others have new automation systems added quickly to support operations, but without full lifecycle security in place. Over time, these gaps accumulate into meaningful risk.
A targeted vulnerability assessment gives you visibility into the weaknesses that could be misused by an attacker, mishandled during maintenance, or simply fail due to outdated software. Any of these situations can slow down production, create safety hazards, or lead to a costly shutdown.
Unlike traditional IT scanning, OT environments demand a more careful and practical approach. Systems must remain stable. Controllers cannot be interrupted. Firmware cannot change without engineering approval. A structured assessment gives you clarity on which risks are real, how serious they are, and what can be done safely to address them.
VULNERABILITY ASSESSMENT IS NOT JUST COMPLIANCE IT’S THE BLUEPRINT FOR RESILIENT OT OPERATIONS.
Why OT Vulnerabilities Matter
In IT, a cyber risk usually threatens data.
In OT, it threatens production, equipment, and people.
Industrial systems run the physical processes that power factories, utilities, energy plants, and transportation networks. A single overlooked issue in a PLC, HMI, or safety controller can set off a chain of problems such as unexpected downtime, product quality deviations, unpredictable equipment behaviour, or even environmental damage. In many cases, it can also slow fulfilment commitments and lead to expensive delays.
Most vulnerabilities are not caused by hackers. They appear naturally over the years of normal operations:
- 1. Old firmware stays in service because downtime isn't acceptable
- 2. Networks become less segmented after upgrades or quick fixes
- 3. Legacy controllers still rely on a password everyone knows
- 4. Firewall rules are relaxed during production pressure
- 5. Vendor access is left open after servicing is complete
- 6. Maintenance changes do not always make it back into documentation
Standards such as IEC 62443, NIST SP 800-82, and NERC CIP expect organisations to know where their risks are and how they are being managed. With an assessment in place, engineering teams can respond confidently when regulators ask about high-risk assets instead of hunting for answers under pressure.
Key Advantages
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1. Visibility where it matters
We review weaknesses where they sit inside the systems that actually run your operations, such as DCS, SIS, PLCs, SCADA, HMIs, and network infrastructure, and explain what those weaknesses mean for real-world reliability. -
2. Focus on operational impact
Not every vulnerability deserves equal attention. We guide your resources toward the ones that could genuinely disrupt availability or safety. -
3. Alignment with recognised frameworks
We connect each finding back to the standards your teams already work with — such as IEC 62443, NIST SP 800-82, and NERC CIP — making it clear how security improvements support compliance expectations. -
4. Avoid future disruptions
Spotting weaknesses ahead of time means you can deal with them quietly, before they turn into alarms or production setbacks that interrupt your schedule. -
5. Clear, shared understanding
Reports are written for engineers, operations leads, and security decision-makers alike, helping everyone align quickly on what needs to happen.
Vulnerability assessment is not just a checklist activity.
It safeguards uptime and builds confidence in the future of your operations.
Deliverables
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1. Detailed vulnerability reporting
Each finding clearly explains where the issue exists, how serious it is, and what level of operational risk it presents, along with practical actions to reduce exposure. -
2. Guided mitigation recommendations
Advice is grounded in plant realities, maintenance windows, vendor dependencies, and change-control rules so the right improvements can be made at the right time. -
3. Prioritised remediation roadmap
Urgent issues are separated from those that can wait, helping you take the safest and most efficient path toward reducing risk. -
4. Audit-ready documentation
Evidence is organised to support regulatory compliance and internal assurance processes, making audit conversations far easier.
Our Approach
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✔ Passive-first methodology
We observe traffic through approved monitoring points, keeping sensitive controllers untouched and ensuring operational stability. -
✔ Active checks only when safe
If a deeper investigation is needed, we coordinate closely with engineering teams so nothing unexpected occurs on the plant floor. -
✔ Validated, real findings
Every major result is verified to prevent wasted effort on false alarms or theoretical issues. -
✔ Practical, action-focused reporting
Recommendations include context and safe execution guidance so work can progress immediately.
Common OT Vulnerability Types & Real-World Risks
In many facilities, exposure builds up quietly:
- 1. Firmware that hasn't been supported in years
- 2. Segments of the network that allow too much movement
- 3. Remote access left on after vendor troubleshooting
- 4. Firewall rules loosened to keep production moving
- 5. Shared credentials are still used on older PLCs
- 6. Engineering fixes were not properly recorded
Each one seems small until the day the wrong combination of changes causes an incident.
A vulnerability assessment uncovers these risks before they show up as operational or safety events.
In IT, downtime threatens information.
In OT, it can stop production or put personnel in danger.
Assessment Scope & Typical Timeline
What We Review
Typical scope includes:
- 1. DCS, SIS, PLCs, and field controllers
- 2. SCADA and HMI workstations
- 3. OT network segmentation and industrial firewalls
- 4. Remote access paths and vendor connectivity
- 5. Firmware status and configuration weaknesses
Where these systems influence process safety or uptime, we may also assess associated servers, historian systems, and industrial wireless links.
How Long Does It Take?
Most assessments fit smoothly into normal operations over about 2–6 weeks:
- Planning and safe-access preparation
- Passive data collection
- Validation and analysis
- Risk correlation
- Reporting and action planning
All performed without interrupting production.
Industries We Support
- Energy and Utilities
- Oil and Gas, both upstream and downstream operations
- Manufacturing and Automotive
- Pharmaceutical Production
- Transportation and Logistics Systems
Any environment that depends on industrial control technology depends on the ability to understand and manage its risks.
Outcomes & Business Benefits
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✔ Remove uncertainty
Instead of guessing what might cause problems, you'll have a verified picture of exactly where risks are sitting in your control environment. -
✔ Reduce wasted effort
Rather than digging through old notes or spreadsheets that no longer match reality, you'll have a current risk record your teams can rely on. -
✔ Ensure compliance readiness
Findings and actions are aligned with industrial regulatory expectations. -
✔ Use engineering time wisely
Your engineers can spend time on issues that could genuinely affect safety or uptime, instead of spreading attention thin across less-important gaps. -
✔ Enable long-term improvement
Lifecycle planning becomes easier when risks are visible and prioritised.
Take Control of Risk Before It Controls Your Operations
Vulnerabilities build slowly through countless changes, a new device here, a temporary fix there. Over time, they become harder to track and easier to overlook.
A professional OT Vulnerability Assessment reveals these issues early and shows you exactly what requires attention, why it matters, and how to act safely.
Speak with Arista Cyber to schedule your OT Vulnerability Assessment.
We help secure the systems that keep your business running.
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