01
Client Profile & Background
A large-scale automotive parts manufacturer in Banten, operating across three production facilities in Tangerang and Serang, with over 2,000 employees and 500+ IoT sensors generating 10 TB of operational data daily. The company relies on SAP ERP, MES, and real-time quality control systems. Their legacy storage infrastructure consisted of direct-attached storage (DAS) arrays from multiple vendors, leading to data silos and management complexity.
The IT team consisted of 15 engineers responsible for maintaining servers, storage, and network. They needed a centralized, scalable storage solution that could support virtualization, high-availability databases, and long-term archival for compliance with ISO 9001 and IATF 16949 standards. The existing environment had no unified backup strategy, relying on manual tape backups performed weekly.
02
Technical Challenge
The primary challenge was the inability to meet recovery time objectives (RTO) and recovery point objectives (RPO). The legacy DAS arrays experienced 12-hour backup failures due to bandwidth bottlenecks, resulting in RPOs exceeding 24 hours. During a critical production run, a storage controller failure caused 8 hours of downtime, costing the company $120,000 in lost production and overtime.
Additionally, the company faced data growth of 30% year-over-year, with no clear path to scale storage without forklift upgrades. The lack of centralized management led to orphaned data and difficulty in provisioning storage for new VMs. Security was also a concern: the storage lacked encryption at rest and had no integrated ransomware protection, making it vulnerable to attacks that could halt production lines.
03
Implemented Solution
Intilogy designed and deployed a tiered storage architecture combining all-flash and hybrid arrays. The core solution included two Lenovo ThinkSystem DM7100F all-flash arrays for mission-critical databases and VDI, connected via Fibre Channel to a VMware vSphere cluster. For secondary storage, we deployed a Synology RS4021xs+ NAS for file shares and archival, with snapshot replication to a second site in Cilegon. Backup was overhauled using Veeam Backup & Replication, with daily backups to a QNAP TS-1685 with 10GbE connectivity. We integrated cybersecurity features including encryption at rest and immutable snapshots to protect against ransomware. The entire solution was managed via a single pane of glass using IT infrastructure monitoring tools. We also implemented HCI principles for the virtualization layer, ensuring seamless scalability.
04
Results & ROI
Post-implementation, the manufacturer achieved a 95% reduction in backup windows: from 12 hours to 35 minutes. RPO dropped from 24 hours to 1 hour, and RTO for critical VMs improved from 8 hours to 15 minutes. The all-flash arrays reduced database query latency by 80%, accelerating production reporting.
The company now supports 500+ VMs with 50 TB of usable capacity, with room to grow to 200 TB without hardware changes. The centralized management reduced storage provisioning time from 2 days to 2 hours. Annual downtime costs decreased by 90%, saving approximately $500,000 per year. The solution paid for itself within 18 months through operational efficiencies and risk mitigation.
