What are the methods to identify and mitigate system vulnerabilities in Systems Engineering?

I would extend the slightly outdated FMEA to the FMECA analysis technique, emphasizing that the true value of such analyses are only really unlocked when true learning occurs(as opposed to superficial process fulfillment); one needs to be willing to have a genuine interest in 'failing fast' and opening up past mistakes to scrutiny from many different views. Failures/mistakes you find need to be celebrated as 'badges of quality culture' , as they are the measurable yardstick for how effective the learning process is. In addition: Systems Modelling(especially with regard to Context) is a fundamental prerequisite for any analysis. If you cannot clearly explain how/where your system shall operate, how will you evaluate performance?

System Vulnerability Analysis is like a sixth sense for Systems Engineers, an indispensable tool that reveals the unseen threats lurking in the shadows of our systems. It's like a guardian angel, constantly watching over our systems and protecting them from harm. It's like a detective, meticulously examining every nook and cranny of our systems for clues that could lead us to vulnerabilities. We become the masters of our systems, with the ability to foresee and mitigate threats before they strike. In a world of ever-increasing complexity and risk, System Vulnerability Analysis is our greatest ally, helping us build systems that are invincible against any adversary.

System Vulnerability emerges from the weaknesses and/or flaws manifesting in a system's components (e.g., sub-systems), in the interactions between and among such components. The said "vulnerability" could also emerge from any disruptions bestowed on the system from a higher-level system (i.e., meta-system); however, those disruptions would depends on the weaknesses and/or flaws in its sub-systems. considering that not everything engineers have created has become successful (i.e., there has been failures, even catastrophic ones), it follows that engineering processes ought to not only design systems but, using tools such as FMEA, to also detect errors and weaknesses that might cause failure in operations.

System Vulnerability Analysis (SVA) is a critical tool in Systems Engineering, allowing us to identify potential weaknesses in design and operation. By employing methods like FMEA, which can be integrated with other processes like APQP, we detect vulnerabilities that could lead to failure. The precise use of SVA not only safeguards against unexpected challenges but also fosters the development of robust and reliable systems. In a field where precision and reliability are paramount, understanding and addressing system vulnerabilities is not just a task; it's a commitment to excellence that shapes our approach to engineering.

I wrote a detailed perspective almost 1200 characters only to find out 750 is the limit and I was not able to post it! "Engineers, start actually working on the stuff you design!!" Edward Kiefer, Airbus A300 Technical Training Instructor Louisville KY. Adios.

System Hardening is like the armor that protects our systems from the relentless onslaught of threats. It's the shield that guards our systems against vulnerabilities, the fortress that keeps intruders at bay. With System Hardening, we transform our systems into impregnable strongholds, capable of withstanding even the most formidable attacks. We become the architects of resilience, designing systems that are not only robust but also unyielding in the face of adversity. System Hardening is like the bedrock upon which we build our systems, ensuring that they stand firm and unshaken, no matter the challenges they face.

Considering the long-term usability of the system, it may prove useful to explore aspects such as "flexibility" (ability to support more than one application) and "extensibility" (ability to be extended to new application). Furthermore, the system designers Designer shall consider that the "performance" of a system will depend on the decisions (rational or otherwise) that people might make about how to use it.

Utilize Security Technical Implementation Guides (STIG) to conduct a STIG applicability session. Once you have identified all the applicable STIGs conduct a walkthrough to identify what settings you will or will not enforce. utilize the SCAP Compliance Checker (SCC) tool and run the STIGs against your devices. Determine what settings you will and will not enforce. For those that you will not, or cannot, enforce, develop mitigation strategies.

In the realm of engineering complex systems, System Hardening is akin to constructing a fortress. It's about building robust defenses through detailed planning and implementation. By refining security settings, eliminating unnecessary exposure, and adhering to a continuous cycle of updates and modifications, vulnerabilities are minimized. This multifaceted process encompasses various components of a system, including hardware, software, network, or data. System Hardening isn't merely a technique; it's a commitment to excellence and resilience that echoes through every phase of design and construction, contributing to the overall integrity and safety of the systems we engineer.

System Resilience is analogous to the engineering of a flexible bridge that can sway with the wind without collapsing. It is the vital quality that allows our systems to adapt, recover, and maintain functionality despite adverse conditions. By integrating attributes like redundancy, diversity, and adaptability, we create not just rigid structures but dynamic entities capable of withstanding failures, errors, or attacks. In my experience with complex systems design, resilience isn't merely a component; it's an intrinsic property that permeates every level of engineering, giving systems the strength to continue operating under unexpected stress or change. It's the principle that guides us in building not just functional but resilient systems.

System Resilience is like a phoenix rising from the ashes, enabling our systems to recover from vulnerabilities with renewed strength. It's the secret sauce that makes our systems unshakeable, allowing them to bounce back from disruptions with ease. With System Resilience, we become the masters of adaptability, engineering systems that can weather any storm and emerge victorious. It's like a superhero's power, giving our systems the ability to heal themselves and continue to function even in the face of adversity. System Resilience is our most cherished ally, ensuring that our systems remain strong, steadfast, and indomitable, no matter the challenges they face.

System Resilience is a methodical approach to how you handle the failures that you can foresee. The more clarity that the designer has on how the product is used in the filed and what misuse scenarios can happen, the better the design to address those scenarios with out the need for some Technician to be involved to fix things. So, there is minimal downtime.

As more and more systems are being used in safety critical applications, we need to start thinking about system resilience in the area of safety risks and security treats as well.

Testing is important to gain confirmation that a system does what it is supposed to do, and doesn't do what it is supposed not to do. However, testing has serious limitations for complex systems. In most practical modern applications, it is impossible to exhaustively test all possible scenarios. While one must try to design tests that cover as many important scenarios as possible, for higher integrity systems, one must look to other systems engineering techniques for assurance that the system will work as required. Modelling and simulation can be helpful for some systems, for others, formal mathematical verification of correctness may be necessary.

A reminder of the great words of Dijkstra: Testing can be used to show the presence of bugs, but never to show their absence! So while system testing may give confidence, largely it only ever demonstrates nominal operation. Anything picked up during system testing really should have been detected much earlier in the lifecycle.

System Testing is like the ultimate trial by fire for our systems, a crucible that reveals their true mettle. It's the ultimate litmus test, uncovering hidden vulnerabilities and weaknesses that could otherwise spell doom. With System Testing, we become the ultimate defenders of our systems, ferreting out flaws and vulnerabilities with surgical precision. It's like a treasure hunt, where the prize is a system that's robust, reliable, and impervious to threats. System Testing is our most trusted companion, helping us ensure that our systems are battle-hardened and ready to face any challenge, no matter how daunting.

System Testing is comparable to a rigorous examination of a complex machine, ensuring all its intricate parts work harmoniously. In the field of aerospace and systems engineering, it's the careful validation and verification process that ensures a system meets its requirements and specifications. Through methods like functional testing, performance testing, and security testing, we are able to uncover potential vulnerabilities. It's an essential practice that helps us to refine and perfect our systems, confirming their readiness for real-world applications. By methodically exposing systems to both normal and stressful conditions, we craft resilient and reliable systems that can stand firm against potential challenges.

System Monitoring encompasses a continuous survey of the system's landscape. In the realm of (aersopace) system design, it functions as a real-time alert system, sensing any abnormalities or potential vulnerabilities. Employing sensors, logs, and other tools, System Monitoring offers an immediate response capability, similar to an attentive lifeguard scanning the waters for disturbances. It's not merely a preventive measure; it's an integral part of sustaining system integrity. Through diligent monitoring and analysis, we obtain crucial insights that guide our steps towards optimization and readiness, ensuring that our systems are perpetually aligned and secure.

System Monitoring is like the all-seeing eye, the vigilant guardian that never sleeps, watching over our systems day and night. It's the heartbeat of our systems, alerting us to the slightest irregularity, the faintest sign of vulnerability. With System Monitoring, we become the sentinels of our systems, always on the lookout for threats that could compromise their integrity. It's like a radar, scanning the horizon for incoming storms, giving us the time and insight to brace for impact. System Monitoring is our most trusted ally, helping us ensure that our systems are always at their peak, ready to face any challenge with unyielding resolve.

The latest methods of system monitoring use data from installed sensors. There are really 3 levels of sophistication: Alarm Level -- These are set as min/max limits that signals shouldn't exceed. Alarms are often used as indicators of imminent failure or to shut down a machine, Trending--Signals that slowly change with time are indicators of change, or Analysis via DigitalTwin--The latest and most sensitive techniques in system monitoring involve developing a virtual model with sensor outputs. Real observed sensor outputs can then be used to infer what is really happening from multiple sensor outputs and typically provide a much earlier warning than alarming or trend-based condition monitoring.

System Auditing is like a magnifying glass that reveals the tiniest cracks in the armor of our systems. It's the detective that uncovers the hidden vulnerabilities, the sleuth that solves the mysteries of our systems. With System Auditing, we become the ultimate investigators, scrutinizing every aspect of our systems for signs of weakness. It's like a spotlight, shining a light on the darkest corners of our systems, revealing the vulnerabilities that lurk in the shadows. System Auditing is our most invaluable tool, helping us ensure that our systems are airtight, invulnerable, and ready to face any challenge with unwavering confidence.

Systems are created to solve problems, to improve operations. While it helps checking "conformance" to requirements and delivery processes, a great place to check and establish the suitability, efficiency, and effectiveness of the system should be at the Post-Implementation Reviews (PIRs), the first of which ought to occur some six to thirty-six months after start-up, when the system has been sufficiently in operations. This approach will allow for performance gaps and other vulnerabilities to have manifested "in real-life", as opposed to "on paper" during the preceding System Analysis steps of FMEA, HAZOP, etc.

System Auditing is akin to a skilled detective meticulously investigating every facet of a system, employing tools like checklists, interviews, and inspections to uncover hidden vulnerabilities. This thorough scrutiny ensures that the system not only meets predefined standards but excels in compliance, effectiveness, and efficiency. It's like a magnifying glass illuminating the finest details, revealing areas for improvement and allowing for the systematic strengthening of the system's armor. System Auditing provides invaluable insights, helping to bridge gaps, enhance quality, and maintain the integrity of the system, preparing it to face any challenges with confidence and resilience.

Systems are designed and implemented to solve specific problems. The purpose and/or objective of the system must be duly established and be kept in mind during the whole process. Too often, engineers and managers jump into providing a solution (i.e., creating a new system) without fully or properly defining what it is they really need to solve (e.g., real needs of the customers).

The interplay and integration of these different methods - system hardening, resilience, testing, monitoring, and auditing - create a multi-layered defense strategy. It's like constructing a fortress with various lines of defense, where each component has a specific role but works in harmony with the others. All these elements together form a robust, dynamic, and adaptable system that can respond to rapidly changing threats and challenges. It underscores the importance of a holistic approach, where no single method is a silver bullet, but their synergy creates a robust and resilient system, capable of withstanding diverse and evolving threats. This complexity and adaptability are essential in today's ever-changing technology landscape.

Based on my experience some of the vulnerabilities of systems are caused because of organizations craving to be the first or beat the competitor, just force the design and testing teams to complete in ridiculously timelines. This will lead to skipping few of the steps during the process which prove catastrophic for the systems during the final integration.