Manufacturing VMware to AWS Migration
- $180K
- Annual Infrastructure Savings
- Zero
- Unplanned Downtime During Migration
- 45 VMs
- Migrated in 3 Weekends
- Eliminated
- Hardware Refresh Cycle
About the Client
A manufacturing company with aging VMware infrastructure facing expensive hardware refresh cycles.
The Challenge
Aging VMware infrastructure requiring $300K hardware refresh with 18-month procurement cycle
Limited on-premises IT staff struggling to maintain 24/7 operations across multiple plants
ERP and MES systems had complex interdependencies making migration planning difficult
Production systems required minimal downtime with strict maintenance windows on weekends only
Network latency concerns between on-premises plant floor systems and cloud workloads
The Solution
Phased VMware to AWS migration using AWS MGN with zero downtime.
AWS MGN | Direct Connect | EC2 | EBS | AWS Backup | CloudEndure
Technical Implementation
Used AWS Application Migration Service (MGN) for automated server replication and cutover
Established AWS Direct Connect for reliable, low-latency connectivity to plant floor systems
Migrated 45 VMs in waves over 3 weekends with rollback capability at each stage
Implemented hybrid architecture keeping time-sensitive plant floor systems on-premises
Configured AWS Backup for centralized backup management across all migrated workloads
Created runbooks for ongoing management and trained internal IT team on AWS operations
Results & Business Impact
- $180K
- Annual Infrastructure Savings
- Zero
- Unplanned Downtime During Migration
- 45 VMs
- Migrated in 3 Weekends
- Eliminated
- Hardware Refresh Cycle
Technology Stack
- VMware
- AWS MGN
- EC2
- EBS
- Direct Connect
- AWS Backup
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