Successfully migrated a manufacturing company's 20-year-old legacy systems to the cloud with zero production downtime and 40% cost reduction.
0 minutes
Migration Downtime
Zero downtime achieved
40% reduction
Infrastructure Costs
$1.8M annual savings
65% faster
System Performance
Response time improvement
The Challenge
Industrial Solutions Corp operated on 20-year-old legacy systems that were becoming increasingly difficult and expensive to maintain, while limiting their ability to scale and innovate.
Legacy mainframe systems with high maintenance costs
Limited scalability for growing business needs
Security vulnerabilities in outdated systems
Lack of integration capabilities with modern tools
High risk of system failures and data loss
Inability to support remote work and modern workflows
Our Approach
Executed a phased cloud migration strategy with parallel systems, gradual data migration, and comprehensive testing to ensure zero downtime.
AWSVMwareOraclePostgreSQLDockerKubernetesTerraform
Implementation Timeline
Total Duration: 32 weeks migration
1
Assessment & Planning
6 weeks
- Legacy system audit and dependency mapping
- Cloud architecture design
- Migration strategy development
- Risk assessment and mitigation planning
2
Infrastructure Setup
8 weeks
- Cloud infrastructure provisioning
- Network connectivity establishment
- Security controls implementation
- Monitoring and backup systems setup
3
Application Migration
14 weeks
- Application refactoring and containerization
- Database migration with synchronization
- Testing and validation in cloud environment
- Performance optimization and tuning
4
Cutover & Optimization
4 weeks
- Final data synchronization
- Production cutover execution
- Post-migration optimization
- Team training and knowledge transfer
Technical Architecture
Hybrid cloud architecture with containerized applications, managed databases, and automated scaling capabilities.
AWS EC2 and ECS for application hosting
RDS for managed database services
CloudFront for content delivery
VPC for secure network isolation
Auto Scaling Groups for dynamic scaling
CloudWatch for comprehensive monitoring
Results & Impact
0 minutes
Migration Downtime
Zero downtime achieved
40% reduction
Infrastructure Costs
$1.8M annual savings
65% faster
System Performance
Response time improvement
10x capacity
Scalability
Auto-scaling capabilities
99.8%
Security Score
45% improvement
Business Benefits
Eliminated technical debt from legacy systems
Improved system reliability and performance
Enhanced security and compliance posture
Increased operational agility and scalability
Reduced maintenance and operational costs
Enabled modern development practices
“The cloud migration was executed flawlessly with zero impact to our production operations. We now have a modern, scalable infrastructure that supports our growth plans while significantly reducing our IT costs.”
Robert Thompson
IT Director, Industrial Solutions Corp
Key Learnings
Phased migration reduces risk and ensures business continuity
Legacy system documentation is often incomplete or outdated
Parallel running systems require careful data synchronization
Team training is crucial for successful cloud adoption
Recommendations
Invest time in thorough legacy system documentation
Plan for parallel systems during critical migration phases
Implement comprehensive monitoring from day one
Prepare for unexpected dependencies and integration challenges
Cloud MigrationLegacy ModernizationManufacturingAWSZero Downtime