Case study
Integration of legacy production equipment into modern ICT system
For an iconic client company in Romania, with legacy production equipment individually connected to dedicated hardware, we have realized the integration into a modern, functional ICT system.
Status quo
Our client, an iconic manufacturing company in Romania, faced challenges in managing traditional manufacturing equipment that was individually connected to dedicated hardware. In order to improve operations, it was necessary to integrate a modern and functional ICT system with optimised monitoring. We also needed to provide staff with the necessary training to operate the new system effectively.
Together with the client company, we defined the following ICT priorities:
- Networking of legacy production equipment;
- Moving from a fragmented, sub-optimal network to an integrated management system;
- Upgrading the ICT system;
- Implementation of new work processes and communications;
- Training users on the new ICT system;
- Consultancy to executive management on ICT system optimisations;
- infinilink full responsibility for the ICT system.
Challenges
1. Networking of legacy production equipment running specific software from multiple third-party industry vendors: Each vendor has its own communication protocols and standards, which can make it difficult to integrate equipment into a single system. That’s why we implemented custom middleware that eliminated communication gaps and enabled seamless integration. This solution required detailed knowledge of industry protocols and communication standards, as well as the ability to develop custom software solutions to integrate legacy equipment into the new system.
Outcome: enhanced process visibility and control, increased productivity, reduced downtime and improved quality control.
2. Moving from a fragmented, sub-optimal network to an integrated management system, design and implementation: The existing client-company network was sub-optimal and fragmented, making it difficult to effectively manage, design and implement new processes. The infinilink team designed and implemented an integrated management system that provides visibility and control over the entire network infrastructure, reducing complexity and fragmentation of the ICT system.
Outcome: improve system performance, increase security and reduce maintenance costs.
3. Upgrading the ICT system: The modernisation of the system required the replacement of multiple hardware and software elements, the integration of old equipment and the implementation of new systems and applications. Very important was that the entire process was carried out without interrupting ongoing operations, with minimal downtime.
Outcome: reduce downtime, improve data management and increase productivity.
4. Implementation of new work processes and communications: Together with the client, we developed new processes that are compatible with the existing system and easy to adopt by the client’s staff. The infinilink team worked closely with client staff to ensure that the new processes optimised efficiency and productivity of operations.
Outcome: increase productivity, reduce errors and improve communication on operations between staff members.
5. Training users on the new ICT system: The successful implementation of the new ICT system depended on the ability of the client’s staff to use it. The infinilink team provided the client’s employees with comprehensive training on the features and functionality of the new system, as well as on-site support to ensure staff could use the system confidently and effectively.
Outcome: increase staff confidence, reduce errors and increase productivity.
6. Consultancy to executive management on ICT system optimisations: The infinilink team has identified ICT areas impacting the client’s business processes that need optimisation. We provide concrete recommendations to the executive management of the client company, leading to continuous improvement of system performance and efficiency.
Outcome: improve system performance, increase efficiency and reduce costs.
7. Full ICT system responsibility for continuous support of business and production processes: To support business and production processes, we ensure that the system is always working optimally. We monitor system performance and take proactive measures to prevent outages and ensure continuity of operations
Outcome: reducing downtime, improving system performance and increasing productivity, with a positive effect on the quality of the client company’s products.
Used technologies
Operating industry-specific systems and integrating them into an ICT management system according to current practices is a critical aspect of any modern company. Complex ICT systems require a high level of expertise to operate efficiently, which can be achieved with a team of skilled professionals to ensure everything runs smoothly and integrates seamlessly.
Heterogeneous, vendor-mixed network: involves the use of multiple vendors for different components of the ICT infrastructure, such as servers, routers, switches and storage devices. The advantage of a heterogeneous network is that it allows the client company to leverage the strengths of different providers to create a customised infrastructure.
Fixed & wireless access solutions: fixed solutions offer a dedicated, high-speed internet connection, while wireless solutions offer flexibility and mobility. For the specific needs of the client company, a combination of fixed and wireless access solutions was required to ensure optimal performance and availability.
Identity Access Management (IAM): multi-factor authentication and role-based access control helps the client company enforce security policies, monitor user activity and reduce the risk of data breaches.
Productivity solutions: tools for communication, collaboration, project management and task automation. It helps the client company streamline workflows, reduce manual tasks and improve communication and collaboration between teams, with significant positive effects on costs and efficiency.
Management / integrated communication security solutions: encryption, firewalls and intrusion detection and prevention systems. These integrated communications security solutions help protect against a wide range of threats, including viruses, malware and phishing attacks.
infinilink services and solutions
Analysis of individual production machine software: we identified the strengths and weaknesses of each software as well as compatibility and interoperability issues between them. We also assessed the potential for improving and optimising the performance and functionality of the software.
Hybrid on-prem and on-cloud solutions: we migrated some of the client’s data and applications to the cloud, while keeping critical ones on their own servers. In this way, we ensured the security, reliability and scalability of the customer’s IT infrastructure.
Implementation and management of a new ICT system. The new system integrates all aspects of the client’s business, from production planning and scheduling to inventory management and quality control. The new system also provides real-time data and analysis as well as user-friendly interfaces and dashboards.
Integration of production machines, including replication of native legacy systems. We replicated the native legacy systems of some of the machines so that they could communicate with the new system without losing their original functionality. We also installed sensors and controllers on some of the machines to allow remote monitoring and control.
Backup/restore system for production machines: automatically creates copies of machine data and settings at regular intervals and stores them in a secure location. The system also allows quick and easy recovery of data and machine settings in the event of a breakdown.
Internal network upgrade: we replaced old cabling and routers with new ones that support higher bandwidth and lower latency. We also configured network settings and protocols to optimise data transmission and reduce network congestion.
Internal network security: we installed firewalls, antivirus software and encryption tools on network devices and servers. We have also implemented access control policies and authentication mechanisms to restrict unauthorised access to the network.
Training and helpdesk for client employees: the infinilink team has conducted training sessions on topics such as equipment configuration, data reporting, system navigation, etc. We offer helpdesk by phone or e-mail to answer any questions or solve any problems that employees may encounter.
Remote management, on-site support and interventions: we remotely monitor system and equipment status. We perform regular remote maintenance and updates to keep the system up-to-date and secure. In the event of any problem that requires physical intervention, our technicians will travel to the customer’s premises as quickly as possible.
The infinilink team integrated traditional production equipment, upgraded the ICT system and implemented new work processes. We have also provided comprehensive training and advice to executive management, taking full responsibility for the ICT system. All of these solutions have resulted in improved system performance, increased efficiency and reduced costs, allowing our client to operate more efficiently and improve their products and services.
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