01
Client Profile & Background
A large manufacturing enterprise based in Bekasi, Indonesia, with over 1,000 employees and a production facility spanning 50,000 square meters. The company relies on an on-premises data center to run critical applications including ERP (SAP), MES (Manufacturing Execution System), and PLC data logging. The existing infrastructure consisted of 15 physical servers (HP ProLiant DL380 Gen9) and 200+ virtual machines managed on VMware vSphere 6.5. Storage was provided by a mix of direct-attached storage (DAS) and a legacy SAN (Dell Compellent). The network backbone used Cisco switches and routers. The data center had been operational for over 8 years, and the company planned to migrate to a new, more energy-efficient facility to support expansion and improve disaster recovery capabilities.
The client engaged Intilogy to plan and execute the migration with minimal downtime. Key requirements included maintaining a recovery point objective (RPO) of less than 1 hour and a recovery time objective (RTO) of under 4 hours for critical systems. The migration had to be completed within a 3-month timeline to align with the new facility's lease start date. The company also wanted to modernize their storage architecture by adopting hyperconverged infrastructure and implement a robust backup solution.
02
Technical Challenge
The primary technical challenge was migrating 200+ VMs with a total of 50 TB of data while maintaining business continuity. The existing environment had several pain points: the legacy SAN had only 12-hour backup windows, and full backups took over 24 hours, causing RPOs of up to 24 hours. Network bandwidth between the old and new data centers was limited to 1 Gbps, which would require over 100 hours for initial data transfer if using traditional methods. Additionally, the client had a complex dependency mapping of applications—some VMs were interdependent, and others had strict latency requirements for real-time PLC communication. The migration needed to be phased to avoid impacting production during peak manufacturing hours (Monday to Friday, 7 AM to 7 PM).
Another challenge was the physical relocation of 15 legacy servers that could not be virtualized due to hardware-specific controllers. These servers required careful shutdown, transportation, and reconfiguration. The client also lacked a centralized backup solution; existing backups were stored on a single QNAP NAS with limited retention. To meet the RPO/RTO targets, we needed to implement a replication mechanism that could handle continuous data changes during the migration window. Furthermore, the new data center had a different IP subnet and VLAN structure, requiring network reconfiguration of all VMs and physical servers without causing IP conflicts.
03
Implemented Solution
Intilogy designed a multi-phase migration plan using VMware vSphere 7.0, Veeam Backup & Replication 11, and Synology RackStation RS3617RPxs for storage. The solution leveraged VMware vMotion and Storage vMotion for live migration of VMs with zero downtime. For the initial bulk data transfer, we used Veeam's backup copy jobs to replicate VM data to a Synology NAS at the new site over a dedicated 10 Gbps link provisioned temporarily. This reduced the initial transfer time from 100+ hours to under 10 hours. We also implemented Veeam's replication for continuous protection during the cutover window, achieving an RPO of 15 minutes.
For the 15 physical servers, we used a combination of Lenovo ThinkSystem SR650 servers at the new site to replace the HP ProLiant. The migration involved a 'lift and shift' approach with careful shutdown procedures over a weekend. We reconfigured the network using Cisco Catalyst 9300 switches with VLAN mapping to match the old environment. To ensure application dependency, we used VMware vRealize Network Insight to map traffic flows. Post-migration, we set up a new backup infrastructure with Veeam backing up to a Synology NAS with a retention policy of 30 days. Finally, we integrated the solution with HCI by deploying a 3-node Nutanix cluster for future scalability.
04
Results & ROI
The migration was completed within the 3-month timeline with zero data loss and only 4 hours of total planned downtime for the physical servers. The RPO for critical VMs improved from 24 hours to 15 minutes, and RTO reduced from 8 hours to under 2 hours. The new infrastructure reduced power and cooling costs by 30% due to the energy-efficient HCI cluster and modern servers. Backup windows decreased from 12 hours to 2 hours, enabling daily full backups. The client also gained the ability to perform non-disruptive disaster recovery tests using Veeam's SureBackup.
From a business perspective, the migration enabled the company to expand production capacity without IT constraints. The new data center supports 50% more VMs without additional hardware. The ROI was realized within 18 months through reduced downtime (estimated savings of $500,000 per year from avoided production halts) and lower operational costs. The client now has a future-proof infrastructure that can easily integrate with hybrid cloud solutions for additional scalability. Overall, the project demonstrated the critical importance of using proven technologies and a phased approach for enterprise data center migration in Indonesia.
