Pentest OT and IoT Systems

Protect your connected devices and industrial infrastructure

Where Are the Typical Vulnerabilities?

Whether it’s smart devices in the office, connected machines in production, or embedded systems in vehicles: Operational Technology (OT) and the Internet of Things (IoT) are essential parts of many business processes today, which also makes them attractive targets for attackers.

A successful attack can have serious consequences, from data leakage and manipulation of control processes to complete system failure. At the same time, OT and IoT systems pose unique challenges: long lifecycles, limited standardization, restricted update capabilities, and often physical access to devices by third parties.

Pentesting Operational Technology (OT)

Securing Industrial Control and Production Systems

Operational Technology (OT), including Supervisory Control and Data Acquisition (SCADA) and Industrial Control Systems (ICS), encompasses systems that monitor and control physical processes, such as those in manufacturing, energy supply, or logistics. Due to their long service life and high availability requirements, OT environments differ from conventional IT systems and require tailored testing approaches. The goal is to increase your production environment’s resilience to targeted attacks without disrupting operations. Common vulnerabilities in OT environments include:

  • Misconfigured access to engineering workstations or HMI systems
  • Weak or missing authentication at interfaces (e.g., remote maintenance)
  • Poorly protected communication protocols (e.g., Modbus, OPC-UA)
  • Outdated or unpatched control components
  • Missing segmentation between IT and OT systems

Our Approach to OT Pentesting

Following a joint kick-off meeting, we analyze your OT infrastructure for vulnerabilities. Either on-site or, where possible, in a lab environment. We focus on realistic attack scenarios, such as external threats or insiders with physical access. The priority is identifying and assessing risks without endangering live operations.

In OT and IoT environments in particular, a specific pentest helps to identify security-critical vulnerabilities before they disrupt processes or endanger systems. A specialized pentest of OT and IoT systems thus creates a robust basis for protecting availability and operational security.

Robin Plugge

Senior Security Analyst & Expert for Pentesting OT and IoT Systems

Pentesting IoT, Embedded, and Hardware Systems

Identifying Attack Surfaces in Connected Devices Early On

IoT devices and embedded systems are used across various domains: for example, in industry, automotive engineering, building automation, surveillance technology, or medical technology. These systems often collect, process, and transmit sensitive data while frequently lacking adequate protection against attacks. Typical vulnerabilities in IoT devices include:

  • Insecure firmware and bootloaders
  • Weak or hardcoded credentials
  • Manipulable hardware interfaces (e.g., UART, JTAG, SPI)
  • Poorly implemented maintenance access or wireless protocols (e.g., BLE, ZigBee, LoRa)
  • Security flaws in web or cloud components
  • Broken access control via interfaces

Our Approach to IoT Pentesting

We analyze the entire attack surface from hardware and firmware to connected cloud systems or mobile apps. Testing is typically conducted in our specialized lab under controlled conditions using dedicated tools and equipment. However, we are also happy to perform assessments on-site under real-world conditions. Both automated methods and manual techniques are used, such as reading memory components, reverse engineering firmware, or analyzing wireless communication.

Are Your Systems Protected Against Attackers?

With our combined expertise in OT and IoT security, we help you identify vulnerabilities early and secure your systems sustainably. Have questions about a specific device or project? Feel free to contact us.

More Insights

More Security for Connected Systems: Pentesting OT and IoT Systems In a Nutshell

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Phone: +49 6102 8631-190
Email: sales@usd.de
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Daniel Heyne
Head of Sales - Security Analysis