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Manufacturing · Case study

Manufacturing group cuts infra cost 32% with Azure migration

Aging on-prem servers, rising CapEx, DR gaps and a 12-hour RTO with no tested runbooks.

Manufacturing
-32%
Infra cost
45 min
RTO
0
Downtime at cutover

The challenge

Aging on-prem servers, rising CapEx, DR gaps and a 12-hour RTO with no tested runbooks.

Our approach

Designed an Azure landing zone, executed a phased lift-and-shift, deployed Site Recovery + Azure Backup, and rolled out cost-governance policies with tag-based budgets.

The client operated three plants across Maharashtra on a decade-old on-prem stack — nightly ERP jobs regularly slipped, patching windows collided with production, and the last DR test failed at hour eight.

We started with a two-week discovery: workload inventory, dependency map, a right-sizing pass against 90 days of perf data, and a landing zone design aligned to CAF (Enterprise-Scale). Governance, identity, network topology and cost guardrails went in before a single VM moved.

Migration ran in three waves — dev/test first, then non-critical prod, then ERP + MES in a scheduled weekend cutover with Azure Site Recovery pre-syncing all deltas. Post-cutover we handed over runbooks, cost dashboards, and a quarterly FinOps review cadence.

Outcome

32% infrastructure cost reduction, RTO from 12h down to 45 minutes, zero-downtime cutover.

"Prime Fixel migrated our on-prem workloads to Azure with zero downtime. The FinOps controls kept us honest."
CIO, Mid-market Manufacturing Firm

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