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By Errin O'Connor, Founder & Chief AI Architect, EPC Group

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ManufacturingAzure

Global Manufacturer Azure Cloud Migration

1,000+ VMs Migrated with 45% Cost Savings

Fortune 500 Manufacturing Company
10 months
15 consultants
1,000+
VMs Migrated
45%
Cost Savings
99.99%
Uptime
60%
Faster Deployment
0
Downtime
100%
On Schedule

Outcome figures on this page are EPC Group engagement data for an anonymized client, recorded by the delivery team at project close. They are not independently audited, and no client-issued measurement is published for them. How EPC Group counts · Documented engagements

Overview

A Fortune 500 manufacturing company needed to modernize their aging on-premises data center infrastructure by migrating to Microsoft Azure. With over 1,000 virtual machines, legacy applications spanning 20+ years, and global manufacturing operations requiring 24/7 uptime, the migration required meticulous planning and execution.

The Challenge

The manufacturing organization faced significant infrastructure and operational challenges:

  • Aging on-premises infrastructure nearing end-of-life with high maintenance costs
  • 1,000+ virtual machines across multiple data centers with complex dependencies
  • Legacy applications requiring refactoring or replacement for cloud compatibility
  • Global manufacturing operations requiring zero downtime during migration
  • Complex networking with hybrid connectivity to plant floor systems
  • Limited cloud expertise within internal IT team

Our Solution

EPC Group designed and executed a comprehensive Azure migration strategy:

1

Phase 1: Discovery & Assessment

Conducted infrastructure discovery using Azure Migrate, application dependency mapping, and cloud readiness assessment.

2

Phase 2: Landing Zone Architecture

Designed Azure landing zones with hub-spoke network topology, ExpressRoute connectivity, and hybrid identity integration.

3

Phase 3: Pilot Migration

Migrated 50 non-critical VMs to validate approach, test connectivity, and train internal teams.

4

Phase 4: Wave Migrations

Executed phased migrations across application tiers using Azure Site Recovery and scripted automation.

5

Phase 5: Optimization

Implemented Azure cost optimization, right-sizing, reserved instances, and Azure Hybrid Benefit.

Results & Impact

1,000+
VMs Migrated
All virtual machines moved to Azure
45%
Cost Savings
Annual infrastructure cost reduction
99.99%
Uptime
High availability achieved
60%
Faster Deployment
Reduced provisioning time
0
Downtime
Zero disruption to manufacturing
100%
On Schedule
Delivered on time and budget

Outcome figures on this page are EPC Group engagement data for an anonymized client, recorded by the delivery team at project close. They are not independently audited, and no client-issued measurement is published for them. How EPC Group counts · Documented engagements

Quick Facts

Client
Fortune 500 Manufacturing Company
Industry
Manufacturing
Service
Azure
Duration
10 months
Team Size
15 consultants

Technologies Used

Azure Virtual MachinesAzure Site RecoveryExpressRouteAzure MonitorAzure PolicyTerraform

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