Cybersecurity in Automation, Test Engineering and critical sectors: Aerospace & Defence

During October, Cybersecurity Month, it is key to emphasise that protecting critical infrastructure goes beyond simply protecting data; it is about ensuring that the operating systems that keep entire industries running are not compromised. Cyber attacks can cause economic losses in the billions, cripple strategic operations or, in the case of sectors such as aerospace and defence, put national security at risk. For companies like EIIT – A Controlar company, cybersecurity is not just an option, but an imperative.

 

Cybersecurity in Automation

The industrial automation environment has changed dramatically in recent years with the convergence of operational technologies (OT) and information technologies (IT). The integration of industrial control systems (ICS), SCADA and IoT devices into plant networks enables a higher level of optimisation, but also exposes systems to new attack vectors. Automation engineers must contend with a threat landscape that requires a specific focus on process security and operational integrity.

Particular risks in automation

Automation and control systems increasingly rely on connectivity and real-time data exchange. However, most OT equipment and networks were designed with the primary focus on availability and reliability, but not on cyber security. This key difference opens the door to several types of threats:

• Denial-of-service (DoS) attacks: SCADA systems and PLCs (Programmable Logic Controllers) are particularly exposed to denial-of-service attacks, where the goal is to stop or slow down critical operations, causing production lines to be interrupted.
• Process manipulation: Attackers can access critical controllers and sensors to alter operating parameters, which can lead to production failures, create defective products or even cause plant accidents.
• OT-targeted ransomware: Ransomware attacks are evolving to specifically target OT environments, crippling entire factories and demanding ransom in exchange for returning control of systems to their operators. This type of attack exploits the lack of proper segmentation between IT and OT networks.

Specific Solutions to Protect Industrial Automation

Automation and control engineers must implement a cybersecurity strategy that goes beyond traditional IT solutions, considering the particularities of OT environments:

• Network Segmentation: It is essential to properly segment OT and IT networks to limit the exposure of critical systems. Implementing industrial firewalls and OT-specific intrusion detection systems (IDS) helps monitor and block unauthorized traffic between different network zones. A focus on security zones and conduits, as proposed in the IEC 62443 standard, is essential to protect the most critical areas of the plant.
• Multifactor Authentication and Access Control: Implement strict authentication and access policies, ensuring that only authorized personnel can modify critical parameters or access controllers. This can include multifactor authentication solutions and role-based access control (RBAC) mechanisms.
• Device-Level Protection: Automation devices (PLCs, RTUs, sensors) often lack native protection systems. Therefore, it is necessary to implement security measures such as communication encryption and regular firmware updates. Ensuring that these devices cannot be tampered with by unauthorized users or external attackers is crucial.
• Continuous Monitoring and Incident Response: Establish a continuous monitoring system that detects anomalous behavior in the OT network. OT cybersecurity solutions should include real-time traffic analysis and event correlation to identify potential intrusion attempts before they become active threats. Additionally, it is necessary to have an incident response plan specific to the industrial environment, including rapid restoration of operations.

Impact on Production: Real Cases and Lessons Learned

Attacks on automation systems are not theoretical. There are several examples of cyberattacks that have paralyzed production plants or manipulated processes:

• Stuxnet: Although it is a well-known example, it remains for many the most important attack in the industrial sector. It was able to alter the operation of PLCs controlling industrial centrifuges, showing how the manipulation of industrial processes can have catastrophic consequences.
• Colonial Pipeline (2021): While this attack focused on IT networks, the impact was felt in OT operations, forcing the company to completely halt its operations. The Colonial Pipeline incident highlighted the importance of greater separation between IT and OT systems and demonstrated how an attack in one area can affect the entire operational environment.
• Norsk Hydro (2019): This global aluminum manufacturer suffered a highly viral ransomware attack that temporarily paralyzed its production. The company chose not to pay the ransom and gradually restored its operations, resulting in important lessons on disaster recovery in industrial environments.

Advanced Considerations for the future

• Industrial IoT Security: As IoT devices continue to proliferate in automation environments, the need for secure communication protocols and remote update mechanisms becomes increasingly critical. The implementation of IoT expands the attack surface, requiring new specific solutions for these devices.
• Virtualization and Hybrid Environments: With the growing adoption of virtualization solutions and the convergence of IT and OT, it is essential to have cybersecurity measures that protect both physical and virtual systems, ensuring that hybrid environments do not introduce new vulnerabilities.
• Cybersecurity Automation: AI and machine learning-based security solutions can automate incident detection and response in industrial networks, enabling real-time protection without constant manual intervention.

This technical deep dive underscores the importance of automation and test engineers adopting a proactive cybersecurity approach, using industry best practices to protect not only data but also the integrity and availability of critical systems. Implementing these solutions not only ensures operational continuity but also competitiveness and resilience in an increasingly connected world.

Cybersecurity in Test Engineering

Test engineering, especially in industrial and high-tech sectors, is a critical process that verifies the quality and performance of products, systems, and software before they go into operation. With the increasing complexity of test environments, cybersecurity has become a fundamental factor in ensuring data protection and system integrity throughout all phases of the testing cycle.

Key Risks in Test Engineering

Test environments, especially automated and distributed ones, present multiple cybersecurity risks. These environments, often used to test complex systems or critical infrastructure, must ensure the security of test data and the reliability of results.

• Interruptions in Automated Testing: Automated testing systems are often connected through local or cloud networks, making them vulnerable to cyberattacks that can interrupt ongoing tests, causing product launch delays and affecting final quality
• Manipulation of Test Data: Sectors such as aerospace and defense require compliance with strict regulations like ISO/IEC 27001, which governs information security management. Ensuring that test systems comply with these regulations is key to guaranteeing security throughout the product development lifecycle.
• Remote Connectivity and Unauthorized Access: As test systems allow remote access to manage and monitor tests from different locations, secure connections are essential. Without proper measures, doors are opened to attacks that could compromise not only the test results but also the system being tested.

Cybersecurity Solutions in Test Environments

Given the critical nature of test engineering, it is necessary to implement a robust set of solutions that protect data, maintain the integrity of the testing process, and ensure that only authorized personnel can access and operate in test environments.

• Segmentation of Test Environments: One of the best practices is to segment test environments so they are separated from other IT and OT systems. This ensures that an attack on the corporate network cannot compromise ongoing tests or associated data. Additionally, test environments should have specific security controls for each phase of the process (development, integration, validation)..
• Data Encryption and Secure Communications: All test data, both stored and transferred between systems, must be encrypted. This prevents malicious actors from accessing critical information or manipulating results. End-to-end encryption ensures that communications between the test system and remote stations are protected from potential interceptions.
• Multifactor Authentication and Access Control: Access to test platforms should be restricted to authorized personnel only. To protect these environments, multifactor authentication (MFA) and strict access control policies should be implemented. This is especially relevant when tests are conducted in distributed facilities or when external engineers need to collaborate on tests.
• Integrity of Test Data:The integrity of test data must be ensured from capture to analysis. Hash solutions and digital signatures can be used to validate that test data has not been altered during storage or transfer.

Considerations for Automated Testing in the Cloud

The transition to cloud testing (Testing as a Service – TaaS) poses new cybersecurity challenges. While the cloud offers scalability and flexibility, it also introduces additional risks, such as exposure to public networks and the possibility of critical test data being vulnerable to attacks.

• Cybersecurity in Virtualized Test Environments: When tests are run in virtualized or cloud environments, cybersecurity measures must be specific to these environments. This includes protecting application programming interfaces (APIs), managing cloud access, and using real-time monitoring solutions to detect potential anomalies in virtual workloads.
• Role-Based Access Control (RBAC): In distributed or cloud test environments, the use of RBAC is essential to ensure that engineers and teams have access only to the resources and test data they need. This minimizes the risk of unnecessary exposure and potential malicious access.

Compliance with Security Regulations and Standards

In sectors such as defense, automotive, or aviation, it is essential to comply with strict cybersecurity regulations and international standards such as:

• ISO/IEC 27001: Provides a framework for information security management, ensuring that test environments comply with rigorous standards in terms of data confidentiality, integrity, and availability
• IEC 62443: This security standard for industrial control systems can also be applied in automated test environments, ensuring that both test data and systems are protected from external threats.

Examples of Attacks and Vulnerabilities in Testing

Unauthorized access or manipulation of test data can cause significant product failures before market launch or generate vulnerabilities in critical systems:

• Firmware and Embedded Systems Manipulation: Test engineers working with hardware, especially in the aerospace or automotive industry, must be vigilant about firmware manipulation during the testing process. A targeted attack could alter the firmware undetected, compromising the security of critical systems such as flight control or navigation systems in aircraft.
• Interference in Software Testing: Software testing systems that rely on remote connectivity are exposed to attacks where attackers can inject malicious data or manipulate results. This can be devastating in sectors where software accuracy is crucial, such as medical devices or air traffic control systems.

Advanced Solutions for Test Engineering

A medida que los entornos de prueba se vuelven más complejos, las soluciones de ciberseguridad también deben evolucionar:

• Continuous Security Monitoring on Test Platforms: Implement real-time security monitoring solutions that detect anomalies during testing processes. These systems, based on machine learning, can identify unusual behaviors that might indicate an attempt to attack or manipulate data
• Testing (Pen-testing): Conduct regular penetration tests in test environments to identify vulnerabilities and fix them before they can be exploited. This includes attack simulations that mimic how a real attacker might compromise test systems.
• Security in CI/CD Testing (Continuous Integration/Continuous Deployment): For teams using CI/CD pipelines, integrating automated security tests (SAST/DAST) in the development and testing phases is key to ensuring that the code passing through tests is free of vulnerabilities.

Impact on Product Quality

Cybersecurity in the Aerospace and Defense Sector

The aerospace and defense sector is constantly evolving, with an increasing reliance on high-tech systems, including communication networks, satellite control systems, aircraft, drones, and missile systems. The complexity of these systems, combined with the integration of advanced technologies such as artificial intelligence, automation, and IoT, has increased their exposure to cyberattacks. Additionally, this sector is a constant target for malicious actors due to the critical nature of military and civilian operations.

Specific Threats in the Aerospace and Defense Sector

Given the sophistication of systems in this sector, threats go beyond traditional attacks and require a comprehensive approach that encompasses multiple layers of security:

• Interference in Navigation and Communication Systems: Aircraft, satellite, and drone control systems rely on GPS signals and other communication systems to operate. Interference, spoofing, or denial of service (DoS) attacks against these systems can cause loss of control, leading to trajectory deviations, loss of communication, or even accidents.
• Unauthorized Access to Weapon Control Systems: Automated weapon systems and defense management systems are under constant threat from malicious actors seeking to access these systems to sabotage or manipulate their operation, potentially compromising the security of military operations.
• Espionage and Intellectual Property Theft: One of the main concerns in this sector is cyber espionage. State actors and advanced cybercriminal groups aim to steal blueprints, software, and R&D data that are critical to maintaining competitive and strategic advantage in the military and aerospace fields.
• Supply Chain Attacks: With the globalization of the supply chain in the aerospace and defense sector, companies rely on a wide network of suppliers. While these chains improve efficiency, they also expose the sector to potential cyber vulnerabilities in their suppliers, allowing for indirect attacks.

Cybersecurity Solutions and Approaches in the Aerospace and Defense Sector

The nature of the systems and the criticality of operations in this sector require a robust and specific security architecture. Solutions must focus not only on protecting IT and OT infrastructure but also on operational resilience and mission continuity.

• Advanced Cyber Defense for Control Systems and Aircraft: Aircraft, satellite, and drone control systems must be protected by multiple layers of security, including specialized firewalls, intrusion detection and prevention systems (IDS/IPS), and high-security authentication protocols. The use of blockchain technologies to validate the authenticity of communications between critical systems has also emerged as a viable solution in the sector
• Encryption and Secure Communications: Defense and satellite control systems rely on secure networks. The use of end-to-end encryption for all communications, especially in military operations, is essential to ensure that sensitive data is not intercepted or manipulated during transit.
• Supply Chain Resilience: To protect the supply chain, it is crucial to implement strict cybersecurity policies for suppliers. This includes validating software and hardware at every step of the process, continuous security audits, and rigorous access controls. Companies should implement the “Zero Trust” methodology, assuming that every element of the chain could be compromised and applying continuous authentication in every interaction.
• Network Segmentation and Isolation of Critical Systems: Critical systems, such as those related to satellite operations or weapon systems, must be segmented from conventional IT networks. This minimizes the risk that a vulnerability in a less critical system could affect vital operations. Defense networks often use physical and logical segmentation, with security zones limiting access to the most sensitive systems.

Examples of Attacks and Lessons Learned

The aerospace and defense sector has been the target of several significant cyberattacks that have exposed existing vulnerabilities and the importance of cybersecurity.

• F-35 Lightning II Data Hack (2017): One of the most well-known cases is the hack of defense contractors working on the F-35 fighter jet program. The attackers, likely linked to a state actor, stole technical information about the aircraft. This incident highlighted the importance of protecting both contractor networks and classified information related to critical projects.
• Ransomware Attacks on Defense Contractors (2020-2021): In recent years, several companies in the defense supply chain have been targeted by ransomware attacks. These attacks not only sought financial ransoms but also aimed to disrupt military operations or steal critical information. This has prompted a more serious approach to network segmentation and disaster recovery in the sector
• Satellite Infiltration: Several reports have indicated attempts to interfere with and gain unauthorized access to satellite control systems used for military and civilian communications. Such attacks can affect intelligence, surveillance, and reconnaissance capabilities, reinforcing the need for advanced cybersecurity measures.

EIIT – A Controlar company’s Approach to Cybersecurity

EIIT – A Controlar company has been at the forefront of implementing secure solutions in its products and services. In the automation sector, we develop systems with robust cybersecurity protocols to ensure that industrial processes are efficient and protected against any type of cyberattack. In the field of test engineering, we use secure platforms that comply with the highest industry standards to protect our clients’ data. In the aerospace and defense sector, we work closely with our partners to ensure that each solution meets the strictest regulations, guaranteeing security at every phase of the project.

Our Solutions

EIIT – A Controlar company develops and provides solutions that integrate advanced cybersecurity measures at all levels. From industrial control systems to test automation, each product is designed to protect critical data and ensure reliable operations.

Innovation and Future

The future of cybersecurity will depend on companies’ ability to adapt to emerging threats. At EIIT – A Controlar company, we continuously work on improving our solutions to ensure that our clients are protected against current and future threats.

Conclusion