01
Client Profile & Background
A large-scale manufacturing company operating across a 50-hectare industrial estate in Bekasi, producing automotive components for both domestic and export markets. The facility includes multiple production halls, warehouses, and administrative buildings, each requiring high-speed connectivity for ERP systems, CNC machines, and real-time inventory tracking. The company had previously relied on a mix of copper Ethernet and Wi-Fi, but faced frequent outages and bandwidth bottlenecks, especially during peak production hours. With plans to implement Industry 4.0 initiatives, including predictive maintenance and automated guided vehicles (AGVs), a more reliable and scalable network was imperative. The estate's existing network infrastructure was outdated, with numerous single points of failure and no centralized management. The IT team consisted of five engineers who spent most of their time troubleshooting connectivity issues rather than focusing on strategic projects. The company needed a partner to design and deploy a fiber optic backbone that could support current and future bandwidth demands, while also integrating with their existing Cisco switches and Synology storage systems.
02
Technical Challenge
The primary challenge was the sheer size of the estate: running fiber optic cables over 1.5 km between buildings required careful planning to avoid signal degradation and ensure minimal interruption to ongoing operations. Additionally, the existing network suffered from intermittent connectivity, with average uptime of only 98.5%, causing production line stoppages costing approximately $10,000 per hour. Latency between the main data center and remote warehouses exceeded 50 ms, hampering real-time inventory updates. The company also needed to support over 200 IP cameras for security, each streaming 4K video, which saturated the previous network. Furthermore, the estate's power infrastructure was unstable, with voltage fluctuations causing damage to networking equipment. The IT team required a solution that could handle power redundancy and provide centralized monitoring. They also needed to comply with industry regulations for data security, especially for sensitive design files transmitted between departments. The existing cybersecurity measures were insufficient, with no segmentation between production and administrative networks.
03
Implemented Solution
Intilogy designed and deployed a fiber optic backbone using single-mode OS2 cables with a ring topology, connecting 12 distribution points across the estate. We installed Cisco Catalyst 9300 switches at the core and Ruijie RG-S2928G-P PoE switches at the access layer to power IP cameras and wireless access points. For redundancy, we implemented dual-homed connections with automatic failover using Fortinet FortiGate 100F firewalls for network segmentation and threat prevention. The fiber runs were buried in conduit with proper grounding to withstand lightning and power surges. To manage the network, we deployed Synology RackStation RS1221RP+ for centralized logging and Veeam Backup & Replication for data protection. The solution also included HCI nodes from Dell VxRail to host virtualized servers for ERP and SCADA systems. All components were integrated into a single pane of glass using VMware vCenter for simplified management. The deployment took 8 weeks with zero downtime during cutover, thanks to meticulous planning and temporary backup links.
04
Results & ROI
Post-implementation, network uptime increased to 99.999%, reducing production downtime by 95%. Latency between buildings dropped to under 1 ms, enabling real-time inventory synchronization across warehouses. The fiber backbone supports 10 Gbps symmetric speeds, with headroom for 40 Gbps upgrades. The company reported a 30% increase in overall equipment effectiveness (OEE) due to reduced network-related stoppages. Additionally, the segmented network improved security posture, with zero successful intrusion attempts in the first year. The ROI was realized within 14 months, primarily from avoided downtime costs. The IT team now spends 70% less time on troubleshooting, allowing them to focus on digital transformation projects. The solution also enabled the deployment of AGVs, which improved material handling efficiency by 40%. The company plans to expand the network to a new 20-hectare plot using the same fiber optic design. For other enterprises considering similar upgrades, Intilogy offers comprehensive server and storage solutions alongside enterprise WiFi to complement the fiber backbone.
