01
Client Profile & Background
A large-scale manufacturing company in Bekasi with over 2,000 employees and multiple production lines producing automotive components. The company operates 24/7 with critical ERP, MES, and supply chain systems. Their data center houses 150 physical servers, many over 5 years old, running diverse workloads including SAP, SQL Server, and custom applications. The IT team consists of 12 engineers managing on-premises infrastructure with limited remote capabilities.
The company had experienced rapid growth, acquiring three smaller factories in the past two years, each with its own legacy IT systems. This led to a heterogeneous environment with varying hardware brands (HP, Dell, Lenovo) and operating systems (Windows Server 2008, Linux). Management wanted to standardize and centralize IT operations to reduce complexity, improve disaster recovery, and support future expansion into smart manufacturing.
02
Technical Challenge
The primary challenge was server sprawl: 150 physical servers with an average CPU utilization of only 12% and memory utilization of 20%. This resulted in excessive power consumption (estimated at 180 kW), high cooling costs, and a large physical footprint occupying 20 racks. Backup processes were failing 30% of the time due to hardware incompatibilities, with full backups taking over 12 hours. The RPO was 24 hours and RTO was 48 hours for critical systems, far exceeding business requirements.
Additionally, the company faced frequent hardware failures—an average of 3 server crashes per month—leading to production downtime. The lack of high availability and failover capabilities meant that a single server failure could halt operations for hours. The IT team spent 70% of their time on break-fix tasks, leaving little time for innovation. Security was also a concern, as many servers were running unsupported operating systems, increasing vulnerability to ransomware. The company needed a solution that could consolidate servers, improve resilience, and reduce operational overhead.
03
Implemented Solution
Intilogy designed a server virtualization consolidation plan using VMware vSphere 7 with vSAN for hyperconverged storage. We replaced 150 physical servers with 8 Lenovo ThinkSystem SR650 nodes, each with dual Intel Xeon Gold processors and 512 GB RAM. The cluster was configured with vSphere HA and DRS for automatic failover and load balancing. For backup, we deployed Veeam Backup & Replication v11 with a Synology RS3617xs as a backup target, enabling instant VM recovery and 15-minute backup windows.
We migrated all workloads using VMware vMotion and Converter, minimizing downtime to less than 30 minutes per server. Legacy Windows Server 2008 systems were upgraded to Windows Server 2019 within VMs. We also implemented disaster recovery to a secondary site using Veeam replication with a 1-hour RPO. Centralized management was achieved via vCenter Server, with monitoring through IT infrastructure tools like PRTG. The entire project was completed in 12 weeks, with full testing and staff training.
04
Results & ROI
The consolidation reduced physical servers from 150 to 8, a 95% reduction in hardware footprint. Power and cooling costs dropped by 80%, saving $120,000 annually. Server utilization increased to 75%, and backup success rate improved to 99.9% with backup windows reduced to 15 minutes. RPO decreased from 24 hours to 1 hour, and RTO from 48 hours to 30 minutes for critical systems. Hardware failures dropped from 3 per month to zero, and IT team time spent on break-fix reduced by 85%, freeing resources for innovation.
The company achieved a full ROI within 18 months. Additionally, the new infrastructure supports future growth: adding new VMs takes minutes instead of days. The standardized environment simplified compliance with industry regulations. The success of this project led the company to engage Intilogy for hybrid cloud integration and cybersecurity enhancements, further strengthening their digital transformation journey.
