penetration testing

Penetration testing is a structured, authorized security assessment in which testers attempt to find and exploit vulnerabilities in systems, networks, applications, or devices. It is used to understand how an attacker could gain unauthorized access, move within an environment, or disrupt operations.

Scope in industrial and regulated environments

In industrial and manufacturing contexts, penetration testing commonly targets:

• IT systems such as ERP, MES, quality systems, data historians, and file servers
• Operational technology (OT) components such as HMIs, PLCs, SCADA systems, and industrial network segments
• Infrastructure including firewalls, VPNs, wireless networks, and remote access solutions used for maintenance or vendor support
• Web applications and APIs used for supplier portals, production dashboards, and engineering tools

Tests are usually performed under strict rules of engagement to avoid unplanned downtime or safety impacts. In high criticality environments, penetration testing may be limited to test systems or digital twins, or to passive and non-disruptive techniques.

How penetration testing is performed

Penetration testing typically includes:

• Planning and scoping: Defining systems in scope, constraints, allowed techniques, and notification paths.
• Reconnaissance: Collecting information about the target environment, such as network ranges, visible services, and technology stacks.
• Vulnerability identification: Using automated tools and manual techniques to find weaknesses, misconfigurations, or outdated components.
• Exploitation: Attempting to actively use vulnerabilities to gain access, escalate privileges, or move laterally, within the agreed limits.
• Post-exploitation analysis: Demonstrating potential impact, such as access to production recipes, quality records, batch data, or control pathways.
• Reporting and remediation support: Documenting findings, technical evidence, and recommendations so the organization can prioritize fixes.

Use with vendors and components

When evaluating vendor components for use in industrial or regulated environments, penetration testing may be:

• Performed by the vendor on its own products, with results shared as part of security documentation or proof assets
• Commissioned by the operator on vendor systems deployed in a representative lab or staging environment
• Conducted by third parties as part of independent security assessments

Penetration testing results are typically combined with secure development documentation, configuration guides, and standards alignment to form a broader view of component security. Test results do not guarantee compliance, safety, or suitability for a specific deployment.

What penetration testing is not

• It is not a full security program or risk management framework.
• It is not continuous monitoring; it represents a point-in-time assessment.
• It is not the same as basic vulnerability scanning, which usually does not include active exploitation or impact analysis.
• It is not by itself evidence of regulatory compliance or certification.

Common confusion

• Penetration testing vs. vulnerability scanning: Vulnerability scans focus on finding known issues using automated tools. Penetration tests go further by manually validating, chaining, and exploiting issues to show realistic attack paths.
• Penetration testing vs. red teaming: Red team exercises often emulate broader attacker campaigns over longer periods, with fewer prior constraints. Penetration tests are usually more tightly scoped and time-boxed.
• IT penetration testing vs. OT security testing: Traditional IT penetration methods may not be safe for production OT systems. OT-focused testing needs additional controls, coordination with operations, and sometimes different techniques.

Operational considerations

In manufacturing environments, planning penetration tests typically involves cross-functional input from IT, OT, safety, quality, and production teams. Key considerations include protecting personnel safety, avoiding production interruptions, aligning with change control procedures, and capturing evidence for internal audits or external assessments.