Managing the security of operational technology is no small feat—I know this firsthand as the CTO of Frenos. As an OT asset owner, you face daily challenges in protecting critical infrastructure while ensuring operations remain uninterrupted. Traditional OT security assessments are often expensive, time-consuming, and even disruptive to production systems. Having navigated these hurdles myself, there is an urgent need for approaches that not only cut costs but also deliver precise, actionable insights without compromising safety. In this post, I’ll share how digital twin technology, enhanced by advanced artificial intelligence, offers a transformative solution for continuous, safe, and cost-effective OT security assessments.
Anyone responsible for an OT network knows that methods designed for IT rarely translate well to industrial systems. Active vulnerability assessments in live environments often involve intrusive scanning that can interfere with critical processes. To mitigate this risk, organizations frequently reduce the scope of their assessments or rely solely on paper-based evaluations. Such methods capture only a moment in time and miss the dynamic threat landscape that affects OT environments.
Moreover, regulatory requirements often mandate that active assessments be conducted in environments that closely mimic production. Building and maintaining these test environments is not only resource-intensive but can also take months to complete, with quality and outcomes varying widely based on the expertise of the assessors involved. Organizations are left with a stark choice: risk disruptions in production or incur heavy investments in test setups that may still fall short of capturing the real state of the network.
Imagine having a virtual model of your entire OT network that mirrors your production system. Now, envision using that model to simulate a wide range of attack scenarios, conduct comprehensive network discovery, and verify which services are accessible, all without ever touching the live environment. This isn’t science fiction. Digital twin technology makes it possible.
This isn’t your traditional digital twin that replicates the OT process, we don’t need that when performing a security assessment. It captures every detail, from operating systems and firmware versions to the intricate web of network connections and open services. By continuously integrating data from real-time configuration updates and change management records, the digital twin remains an accurate reflection of your actual network.
Here’s where the “ah-ha” moment comes in. When you combine this precise virtual model with advanced artificial intelligence, you unlock the ability to interact with your network in ways that were previously unimaginable. Instead of performing active vulnerability scans or penetration tests, the digital twin mimics connections and uses configuration data to identify possible weaknesses within the environment. This method allows you to simulate how your system would react to different attack vectors, observe potential vulnerabilities as they emerge, and gain insight into the network’s behavior under stress, all without incurring the risks and costs associated with testing in a live environment.
For a digital twin to be truly effective in OT security, it must replicate every critical aspect of the production system’s baseline configuration. This includes not only the software and firmware configurations but also the logical network structure, every open port, every active service must be represented accurately. Continuous updates ensure that the digital twin stays in sync with any changes in the live environment.
By leveraging established data integration methods and machine learning techniques, the digital twin can serve as a reliable sandbox for testing. In this safe, virtual environment, tools can simulate network discovery, port scanning, and vulnerability identification without ever affecting live operations. This breakthrough provides organizations with a level of assessment fidelity that previously required risky live testing or prohibitively expensive test environments.
Throughout my career, I have witnessed assessments that took months to complete due to heavy reliance on manual processes, inconsistent expertise, and the high costs of maintaining realistic test environments. The best assessments I encountered combined multiple discovery tools with expert manual validation. These assessments produced reports that clearly defined the scope, explained what was evaluated and what was not, and provided detailed context for every finding along with clear, actionable recommendations.
Now, imagine if such a comprehensive assessment, once an expensive, months-long process, could be completed in just a few days. This vision is no longer out of reach. By leveraging digital twin technology alongside an advanced analytical engine that embodies years of expert knowledge, the assessment process becomes fixed-cost, repeatable, and highly consistent. Instead of outcomes varying widely depending on individual assessors, you obtain a reliable, real-time snapshot of your OT network’s security posture. This continuous feedback loop becomes a single source of truth that informs your cybersecurity strategy. It exposes false assumptions about your network’s as-built condition, links findings directly to policy or compliance gaps, and drives strategic decisions for improvement.
Integrating digital twin technology into OT security assessments brings a host of benefits. The risks associated with active testing in live environments are minimized, as assessments occur in a controlled virtual replica that mirrors production. This enables more frequent and comprehensive testing while maintaining operational continuity.
Traditional assessments often come with unpredictable costs and variable outcomes. In contrast, the digital twin approach offers consistent, repeatable results at a fixed cost. The automation and intelligence built into the system reduce human error and ensure that every assessment is thorough and actionable. In real-world terms, this means vulnerabilities are identified and addressed far more quickly, allowing for proactive measures rather than reactive fixes. Instead of waiting for an annual or triennial test, you receive near-real-time insights that empower rapid responses to emerging threats.
Digital twin technology, powered by advanced artificial intelligence, is redefining how OT security assessments are conducted. By creating an accurate virtual replica of your production environment, you can perform thorough, continuous assessments without risking downtime. This innovative approach not only meets technical and regulatory challenges but also transforms security assessments into a dynamic resource that informs your overall cybersecurity strategy. With this breakthrough, what once required months of work and significant financial outlay can now be achieved in days, ensuring that your OT environment remains secure, resilient, and ready to face an evolving threat landscape.