Hybrid Cloud Connects Plants with Faster Insights and 20% Lower Support Costs

A discrete manufacturer modernised its multi-plant infrastructure with a hybrid cloud platform that centralised analytics and management while keeping latency-sensitive workloads at the edge, reducing plant insight times from hours to minutes, provisioning new environments in under two hours and lowering infrastructure support run-rate by approximately 20%.

About the Client

A discrete manufacturer operating multiple plants with separate infrastructure, engineering systems and reporting environments, requiring greater consistency and enterprise-wide visibility without compromising plant operations.

At a glance

Industry
Manufacturing
Engagement / Service
Cloud Transformation & Hybrid Cloud Modernisation
Coverage
Multiple manufacturing plants
Challenge
Independently managed plant infrastructure, isolated production data and concerns around OT security, network reliability, latency and operational continuity limited the manufacturer’s ability to standardise and scale cloud capabilities.

Success highlights

  • Hours to minutes Plant insight availability
  • Under two hours New environment provisioning
  • All plants Common platform controls
  • Approximately 20% lower Infrastructure support run-rate

The challenge

Corporate meeting

Connecting Plants Without Disrupting Critical Operations

The constraint: independently managed plant infrastructure, isolated production data, OT security and latency concerns

Each plant managed local servers and applications independently, creating inconsistent controls, high support effort and slow rollout of improvements. Any change or fix had to be replicated manually across sites, with no shared platform to standardise how infrastructure was deployed or maintained.

Production information also remained isolated across MES, historian, quality and maintenance systems, limiting enterprise-wide visibility. Concerns around OT security, network reliability, latency and operational continuity further complicated any move toward a shared cloud foundation, since production environments could not tolerate the risk of disruption that a poorly planned migration might introduce.

Our approach

Combining Edge Processing With Centralised Cloud Intelligence

TECEZE designed a hybrid cloud architecture that retained latency-sensitive control workloads at the edge while centralising analytics, integration and management services. The approach created common infrastructure patterns across plants while maintaining secure connectivity and operational continuity.

The approach included:

Hybrid Cloud and Edge Architecture

Designed a hybrid architecture that kept latency-sensitive control workloads at the edge while moving analytics, integration and management capabilities into centralised cloud environments.

Standardised Plant Connectivity

Created a common landing zone, network segmentation model and secure edge gateway pattern for controlled plant-to-cloud data movement.

Industrial Data Platform

Established an industrial data platform using streaming ingestion, time-series storage and governed data products covering production, quality and energy-use information.

Automated Operations and Recovery

Automated environment provisioning, patching, backup, policy enforcement, cost allocation and disaster-recovery testing across plants to improve consistency and reduce support effort.

Technology and Tooling

The transformation combined hybrid cloud and edge infrastructure with an industrial data and operations toolchain to support secure, standardised delivery across plants:

Category Components
Cloud & Edge Azure/AWS hybrid cloud, edge Kubernetes, IoT gateway, private connectivity
Industrial Integration MQTT/OPC-UA integration, event streaming, time-series database, data lakehouse
Edge & Infrastructure Management Azure Arc/AWS IoT Greengrass, Terraform, Ansible
CI/CD & Data Pipelines GitHub Actions, Azure Data Factory or Glue, Databricks
Monitoring & Security Grafana, Microsoft Sentinel/Splunk
The Results: Following Implementation Across Multiple Plants

Faster Plant Intelligence, Standardised Controls and Lower Support Costs

MinsPlant Insights, Down From Hours
<2 HrsNew Environments Provisioned
~20%Lower Infrastructure Support Run-Rate
Hours to MinutesPlant insights reduced from hours to minutes
Under 2 HoursNew environments provisioned in under two hours
All PlantsCommon platform controls established across all plants

What the client says

“The hybrid cloud approach has helped us connect plant operations with enterprise-level intelligence without compromising the systems that production depends on. Standardised controls and automation have also made our infrastructure easier to manage across plants.”

—VP of Manufacturing IT

Delivery partnership

How Teceze Executes on This Engagement

TECEZE worked with the manufacturer’s infrastructure, engineering, OT and operations teams to establish a consistent hybrid cloud model across plants. The delivery combined edge computing, secure connectivity, industrial data integration and cloud automation while keeping critical production workloads close to where they operate.

Looking ahead

Extending Connected Plant Intelligence

The hybrid cloud foundation provides a platform for expanding connected-plant capabilities across additional production, quality, maintenance and energy use cases. As more plant data is brought into governed data products, the manufacturer can build further analytics and operational intelligence while maintaining the established edge, security and continuity model.

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