GSaralCloud conducted an AWS MAP-aligned MRA for a precision components manufacturer operating five plants across Germany and Eastern Europe, focusing on observability, OT-IT integration, and a unified monitoring foundation for 180+ workloads spanning ERP, MES, and shop-floor systems.
The client is a mid-size precision components manufacturer headquartered in southern Germany, supplying the automotive, industrial automation, and medical device sectors. The company operates five production facilities across Germany, Czech Republic, and Poland, employing roughly 2,800 staff and generating annual revenue of approximately €420 million.
Each plant had grown its own IT estate over time — local ERP modules, manufacturing execution systems, shop-floor data collectors, and SCADA gateways — resulting in a fragmented infrastructure where central IT had limited visibility into network behaviour, system performance, or workload dependencies. Plant downtime, when it occurred, was diagnosed reactively rather than predicted, and central reporting depended on manual data collection across plants.
The manufacturer's central IT team faced a recurring, expensive problem — when a plant reported a slow-running MES screen or a stalled production data feed, no central monitoring system existed to diagnose the issue, and engineers had to travel to the plant to investigate. The leadership team identified observability and unified monitoring as the foundational gap that needed to be closed before any cloud migration could deliver real operational value.
"Five plants, 180+ workloads, and zero unified observability — central IT had no real-time view of network performance, no automated alerting on shop-floor systems, and no single dashboard reflecting the health of the company's manufacturing technology estate."
GSaralCloud delivered an AWS MAP-aligned MRA over nine weeks, with observability and operational visibility as the engagement's design centre. Auvik was deployed across all five plants for unified network discovery and real-time topology mapping, while AWS Migration Hub aggregated workload-level data — together producing the manufacturer's first complete, real-time picture of its entire IT and converged-OT estate.
The engagement was structured around discrete phases, each producing actionable deliverables that the client could carry forward independently or roll into the migration execution phase.
Rolled out Auvik across all five plants in three weeks. Captured live network topology, real-time performance data, and a 30-day baseline of bandwidth, latency, and error rates per plant.
Layered AWS Application Discovery Service on top of Auvik for application-level telemetry. Aggregated 180+ workloads into AWS Migration Hub for a unified view.
Ran six joint workshops between IT and Operations Technology owners to formalise the OT-IT boundary, network zones, and data-flow contracts using the ISA-95 reference model.
Designed an AWS-native observability stack — CloudWatch, X-Ray, Managed Grafana, Managed Prometheus — with hybrid bridging to legacy plant systems.
Built a three-year hybrid TCO model that separates plant-edge compute from regional AWS workloads, recognising that some shop-floor systems remain on-prem indefinitely.
Delivered a five-wave roadmap aligned to plant production calendars, with migration windows scheduled around scheduled shutdown periods to minimise production risk.
The MRA gave the manufacturer something it had never possessed in two decades of operation — a single, real-time, end-to-end view of every plant, every workload, and every network path that mattered to production. Cloud migration moved from an unjustifiable abstraction to a measurable programme with quantified before-and-after telemetry.
The engagement also produced the manufacturer's first formal OT-IT Convergence Charter, established the central Cloud & Observability Practice, and defined the eight-engineer training pathway across AWS, Auvik, and managed Prometheus — building the operating capability needed to sustain the new estate without external dependency.
The MRA engagement combined assessment tooling, target-state architecture services, and industry frameworks to produce a complete, validated picture of the client's cloud readiness.
"We had spent years arguing about cloud migration without ever having an honest baseline of how our plants actually performed. Auvik changed that in three weeks, and GSaralCloud built the assessment around that visibility. Our executive board approved the migration programme not because of a slide deck — but because for the first time, we could show them what was happening across all five plants in real time."