A manufacturer connected six plants with zero line downtime

A manufacturer running six plants had six islands of technology. Each site had grown its own network, its own machines and its own quiet vulnerabilities. Head office had almost no real-time visibility into any of them.

The challenge

The board wanted connected, data-driven manufacturing — predictive maintenance, live production dashboards, a single view across sites. But the shop floor runs on machines that cannot simply be rebooted, and any misstep on the plant network risked stopping a line. In manufacturing, a stopped line is money burning by the minute.

What we did

• Mapped the IT and OT estate at every site before touching anything, so we understood the real dependencies.
• Designed a segmented network that connected the plants while isolating fragile control systems from broader traffic.
• Rolled out changes plant by plant, in maintenance windows, with a tested rollback for every step.
• Deployed unified monitoring so head office finally had one live view across all six sites.

The outcome

All six plants were connected into one secure, observable network without a single minute of unplanned line downtime. Network incidents dropped by 40% as fragile, undocumented setups gave way to a designed and monitored estate. With live data flowing to head office, the manufacturer could finally begin the predictive-maintenance programme the whole effort was meant to enable.