Use Case: Breaking Point Analysis of IT and OT Infrastructure via Cyber Range Simulations

A leading steel manufacturing and casting company partnered with our team to conduct a comprehensive breaking point analysis across its integrated IT and OT infrastructure. The engagement leveraged advanced cyber range simulations, structured red-blue team exercises, and critical data classification workshops to assess resilience, identify vulnerabilities, and establish operational thresholds under simulated threat conditions.

Scope of Engagement

• IT Domain: Enterprise networks, business systems, cloud environments, and corporate endpoints
• OT Domain: Industrial control systems, SCADA networks, programmable logic controllers, human-machine interfaces, and plant-level automation assets

Methodology

• Cyber Range Simulations: A controlled, high-fidelity environment was used to emulate real-world cyberattacks such as ransomware, lateral movement, and supply chain compromise without impacting live operations
• Red Team Exercises: Offensive tactics targeted both IT and OT assets to uncover systemic weaknesses, pivot paths, and failure thresholds
• Blue Team Responses: Defensive teams deployed detection, containment, and recovery strategies to validate incident response readiness across domains
• Data Classification Workshops: Digital assets were categorized by business criticality, exposure risk, and recovery priority, spanning ERP systems to production line controllers

Key Outcomes

• Vulnerability Mapping: Identified cross-domain attack surfaces, especially IT–OT convergence points such as remote access gateways, shared authentication systems, and unsegmented networks
• Resilience Benchmarking: Established clear breaking points where business continuity, safety, and data integrity could be compromised under advanced persistent threat scenarios
• Security Hardening Recommendations:
  
  • Network segmentation between IT and OT zones
  • Role-based access controls and multi-factor authentication
  • Real-time monitoring of OT telemetry and IT logs
• Incident Response Protocols: Developed tailored playbooks for coordinated IT–OT response, including escalation paths, forensic readiness, and recovery sequencing

Business Impact

• This integrated analysis significantly enhanced the client’s cybersecurity posture by:
  
  • Strengthening operational continuity across manufacturing and business systems
  • Aligning IT–OT security controls with regulatory and safety standards such as NIST CSF and IEC 62443
  • Empowering leadership with actionable intelligence for strategic risk mitigation

Use Case: Integrated IT–OT As-Is Posture Assessment for Japanese Industrial Gas Conglomerate

Our team conducted a comprehensive IT–OT As-Is Posture Assessment for the Indian subsidiary of a leading Japanese industrial gas and diversified chemicals conglomerate. The engagement focused on evaluating the current-state infrastructure, security controls, and operational capabilities across both enterprise IT systems and plant-level OT environments supporting manufacturing and distribution operations.

Assessment Scope

• IT Landscape: Enterprise network architecture, server and database environments, business applications, identity and access management, and cybersecurity frameworks
• OT Landscape: Industrial control systems (ICS), SCADA networks, programmable logic controllers (PLCs), human-machine interfaces (HMIs), and automation assets across production and distribution sites

Approach and Methodology

• Conducted detailed documentation and mapping of hardware and software assets, data flows, and business-critical systems across IT and OT domains
• Assessed security configurations, patch levels, and access controls for both corporate and plant-level systems
• Evaluated segmentation and convergence points between IT and OT networks to identify potential lateral movement risks
• Benchmarked current practices against global standards including NIST CSF, IEC 62443, and corporate governance policies
• Reviewed compliance posture with respect to regulatory mandates, data protection norms, and operational safety requirements

Key Deliverables

• A unified current-state architecture map covering IT and OT assets, interdependencies, and exposure points
• A risk assessment matrix highlighting vulnerabilities, threat vectors, and operational impact across domains
• Strategic recommendations for:
  • Infrastructure modernization and cloud readiness
  • Enhanced network segmentation and zero-trust architecture
  • OT-specific security controls including anomaly detection and secure remote access
  • Governance alignment and incident response protocols tailored for hybrid environments

Business Impact
This integrated posture assessment empowered the organization to:

• Establish a clear baseline for future digital transformation initiatives
• Strengthen cyber resilience across both enterprise and industrial operations
• Prioritize remediation efforts based on risk, criticality, and business impact
• Align IT–OT security strategies with operational continuity, safety, and regulatory compliance

Use Case: Email Forensics Investigation for a Heavy Industrial Equipment Manufacturer

Zettawise conducted a targeted email forensics investigation for a leading manufacturer of heavy industrial heating and melting systems. The engagement was initiated following anomalies in email communications that raised concerns about potential compromise of operational workflows and vendor coordination.

Given the organization's deep integration of IT systems with plant-level OT environments, the investigation extended beyond traditional email threat analysis to assess potential lateral risks to industrial control systems and production continuity.

Key Focus Areas

• Analyzed email headers, metadata, and payloads to trace phishing attempts and spoofed communications targeting engineering and procurement teams
• Identified unauthorized access patterns and credential misuse that could have bridged into OT networks via shared authentication systems
• Assessed risks to production scheduling, remote diagnostics, and vendor-linked PLC configurations communicated via email channels
• Delivered a remediation roadmap including email hygiene protocols, multi-factor authentication enforcement, and segregation of IT–OT communication pathways

Outcome
The forensic analysis enabled the organization to contain the threat, reinforce trust across its vendor ecosystem, and implement safeguards to prevent future compromise of operational workflows. The engagement highlighted the critical role of securing digital communication channels that interface with industrial environments.

GDRFA Smart Channel Success

Challenge: UAE's General Directorate of Residency and Foreign Affairs needed to ensure the security of their groundbreaking contactless identity verification system.

Our Solution: Zettawise delivered comprehensive end-to-end security testing across the entire ecosystem:

• Complete assessment of 20+ web applications
• Security validation of mobile applications
• Analysis of third-party integrations and APIs

Impact: Secured a national-priority system that processes millions of citizen and resident identifications daily, protecting critical border security infrastructure.

Dubai Health Authority: Protecting Public Health Systems

Challenge: DHA required robust security for their unified Medical Fitness System (SALEM) used by healthcare facilities throughout Dubai.

Our Solution: Zettawise conducted thorough vulnerability assessment and penetration testing across:

• Core SALEM portal infrastructure
• 30+ user roles and access controls
• Multiple integrated applications
• Supporting digital infrastructure

Impact: Safeguarded sensitive health data and ensured the integrity of Dubai's public and private healthcare information systems.

Noqodi: Securing Financial Transactions

Challenge: This Emaratech fintech company needed to protect their electronic payment infrastructure that serves 40+ government entities.

Our Solution: Zettawise performed comprehensive security assessments of:

• Customer portal vulnerabilities
• Merchant portals and back-office systems
• Mobile applications
• Payment infrastructure (V1 and V2 APIs)

Impact:
Protected the financial ecosystem handling millions in daily transactions across e-wallet, direct payments, online portals, and point-of-sale systems.