OT segmentation validation across three manufacturing plants

Segmentation testing between corporate IT and plant OT networks proved that a single engineering workstation bridged both environments, contradicting the documented architecture.

Client: Industrial manufacturer with 3 plants and mixed legacy OT
Duration: 2 weeks on site
Headline issue: Dual-homed engineering workstation bridging corporate IT and plant OT
Sector: Industrial & OT

The challenge

Documentation claimed strict IT/OT separation, but no one had validated it since a network refresh two years earlier.

Our approach

Validated every documented boundary with traffic-level evidence rather than configuration review alone.
Used passive techniques on production OT segments; active testing only on an engineering replica.
Mapped each verified path back to the client's architecture diagrams.

Outcome

Bridging workstation removed and replaced with a jump host and MFA.
Architecture diagrams corrected against evidence.
Annual segmentation validation added to the compliance calendar.

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