01
Client Profile & Background
Our client is a leading automotive parts manufacturer based in Bekasi, West Java, with additional production facilities in Karawang and Surabaya. The company employs over 5,000 workers and operates 24/7 to meet the demands of major automotive brands. Their IT infrastructure supports critical applications including ERP (SAP), MES (Manufacturing Execution Systems), and real-time quality control systems. The network connects three factories, two warehouses, and a headquarters office, handling data from thousands of IoT sensors on the production floor.
Prior to modernization, the client's network was a flat, non-redundant architecture using legacy switches and routers from a single vendor. The core network operated at 1 Gbps, with limited segmentation and no centralized management. As the company expanded, they faced frequent outages, high latency between sites, and security vulnerabilities that could disrupt production. The IT team spent excessive time troubleshooting connectivity issues rather than focusing on innovation.
02
Technical Challenge
The client's network was plagued by several critical issues. First, the core switch experienced a 12-hour outage due to a firmware bug, halting production entirely. Second, inter-site latency averaged 50 ms, causing delays in real-time data replication between factories. Third, the flat network allowed a malware infection to spread from an office PC to the MES server, resulting in 8 hours of downtime. Fourth, bandwidth was insufficient: the 1 Gbps link to the headquarters became saturated during peak hours, impacting video conferencing and cloud backups.
Additionally, the client had no network segmentation for IoT devices, exposing critical systems to potential attacks. The lack of centralized monitoring meant that issues were often detected only after user complaints. The client needed a network that could support 10 Gbps core speeds, sub-10 ms latency, and granular security policies to isolate production, office, and guest networks. They also required high availability with less than 5 minutes of downtime per year.
03
Implemented Solution
Intilogy designed and deployed a comprehensive network modernization solution. The core network was upgraded to a 10 Gbps fiber backbone using Cisco Catalyst 9300 switches with StackWise virtualization for high availability. At each site, we deployed Fortinet FortiGate 600F firewalls with SD-WAN capabilities to optimize traffic between locations and provide advanced threat protection. For edge switching, we used Ruijie RG-S2900 series switches, which offered cost-effective 10 Gbps uplinks and PoE+ for IoT devices.
We implemented network segmentation using VLANs and VRF-lite, isolating production, office, and guest traffic. A centralized network management platform, Cisco DNA Center, was deployed for monitoring, automation, and assurance. We also integrated the network with the existing cybersecurity stack, including endpoint detection and response (EDR) and SIEM. The SD-WAN solution provided dynamic path selection, ensuring optimal performance for critical applications like SAP and VoIP. Redundant ISP links (primary fiber, backup 4G LTE) were configured with automatic failover.
04
Results & ROI
Post-modernization, the client achieved dramatic improvements: network uptime increased to 99.995%, with zero unplanned outages in the first six months. Inter-site latency dropped from 50 ms to under 5 ms, enabling real-time data synchronization between factories. Bandwidth capacity expanded to 10 Gbps at the core, eliminating congestion even during peak hours. The segmented network prevented lateral movement of threats; a subsequent malware incident was contained to a single VLAN without affecting production.
The IT team's troubleshooting time decreased by 70% thanks to centralized monitoring and automation. The SD-WAN reduced MPLS costs by 40% by leveraging cheaper broadband links for non-critical traffic. Overall, the network modernization delivered a 300% ROI within 18 months, factoring in reduced downtime, increased productivity, and lower operational expenses. The client now has a future-ready network that can scale to support Industry 4.0 initiatives, including AI-driven quality inspection and autonomous guided vehicles (AGVs).
