factory Infrastructure & Network

ICS/OT Security Assessment

Your Factory Floor Is Connected to the Internet. Is It Protected?

Industrial control system and OT security assessment for Indian manufacturing and critical infrastructure. SCADA, PLC, HMI testing aligned with IEC 62443 and NIST SP 800-82.

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What Is ICS/OT Security Assessment?

ICS/OT Security Assessment evaluates the cybersecurity posture of your industrial control systems — SCADA (Supervisory Control and Data Acquisition), PLCs (Programmable Logic Controllers), HMIs (Human-Machine Interfaces), DCS (Distributed Control Systems), and the network infrastructure connecting them.

India's manufacturing sector is rapidly digitising — Industry 4.0 initiatives, IoT sensors, remote monitoring, and cloud-connected industrial systems are becoming standard. But this connectivity creates a critical security challenge: systems designed for isolated networks 20 years ago are now connected to corporate IT networks and, often, to the internet.

A cyber attack on industrial systems does not just steal data — it can halt production lines, damage physical equipment, contaminate products, create safety hazards for workers, and cause environmental incidents. The consequences are physical, not just digital.

Why Your Business Needs This

Indian manufacturing is a prime target for cyber attacks. The sector accounted for 25% of all ransomware attacks in India in 2024. The convergence of IT and OT networks means that a phishing email to an office employee can potentially reach systems controlling physical processes on the factory floor.

Common ICS/OT security issues we find in Indian manufacturing environments include flat networks with no segmentation between IT and OT, default credentials on PLCs and HMIs that have never been changed, Windows XP and Windows 7 systems running critical control applications with no patches, remote access solutions with weak authentication providing direct access to control systems, and no monitoring or logging of OT network traffic.

For power, water, oil and gas, and other critical infrastructure sectors, CERT-In has issued specific directives requiring security assessments of industrial control systems. Non-compliance creates both regulatory and safety risks.

What You Get

check_circle IT/OT boundary security assessment — how well is your OT network isolated?
check_circle SCADA, PLC, and HMI vulnerability assessment using OT-safe testing methods
check_circle Network segmentation evaluation — Purdue Model compliance
check_circle Remote access security review for OT environments
check_circle IEC 62443 and NIST SP 800-82 compliance assessment
check_circle Practical remediation roadmap that accounts for OT uptime requirements

Our Approach

OT Environment Discovery (Day 1-3): Non-invasive asset inventory using passive network monitoring and documentation review. We map every device, protocol, and communication path in your OT environment without active scanning that could disrupt operations.

Network Architecture Assessment (Day 3-6): Evaluation of IT/OT boundary controls, network segmentation (Purdue Model compliance), firewall rules between zones, and remote access mechanisms.

Device Security Assessment (Day 6-10): Assessment of PLCs, HMIs, SCADA servers, and engineering workstations for default credentials, firmware vulnerabilities, unnecessary services, and configuration weaknesses — using OT-safe methods that do not disrupt production.

Risk Assessment and Remediation Plan (Day 10-14): Findings prioritised by safety impact, production impact, and exploitability. Remediation recommendations account for OT constraints — we do not recommend changes that require production downtime unless absolutely necessary.

Real Results for Indian Businesses

A pharmaceutical manufacturing plant in Pune discovered that their production SCADA system was accessible from the corporate Wi-Fi network — any employee or visitor with Wi-Fi access could potentially interact with production control systems. Network segmentation was implemented in 2 weeks without production downtime.

An automotive components manufacturer in Chennai found that 34 out of 40 PLCs on their factory floor had default vendor passwords. Remote access to the engineering workstation used a single shared VPN credential for 8 engineers. Our assessment led to a comprehensive OT security programme including network segmentation, credential management, and monitoring.

A power utility in Maharashtra engaged us for IEC 62443 compliance assessment of their SCADA infrastructure. We identified 47 control gaps across 4 substations, and the utility achieved compliance within 6 months using our phased remediation plan.

Frequently Asked Questions

Will your testing disrupt our production?expand_more
No. We use OT-safe assessment methods — passive network monitoring, configuration review, and non-invasive testing. We never send active probes to PLCs or control devices. All potentially disruptive tests are only performed during scheduled maintenance windows with explicit approval.
Do you test SCADA and PLC systems directly?expand_more
We assess their configurations, firmware versions, authentication settings, and network exposure — but we do not actively exploit industrial control systems. OT security assessment requires a different approach than IT penetration testing, and we prioritise safety above all else.
Which standards do you assess against?expand_more
We primarily use IEC 62443 (industrial cybersecurity) and NIST SP 800-82 (Guide to ICS Security). We also map findings to CERT-In directives and industry-specific requirements.
Can you help implement OT security controls?expand_more
Yes. We provide implementation support for network segmentation, monitoring deployment, access control improvements, and ongoing OT security programme development. We work within your maintenance schedules and production constraints.

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