Case StudyManufacturingNetwork InfrastructureCybersecurityManaged IT Services
Ten Weeks to Replace a Plant Network: How a Manufacturer Got SAP Live On Time
When a global manufacturer needed to replace its entire U.S. facility network before a critical SAP deployment, Secureway IT delivered a complete network transformation in just 10 weeks, without losing sight of production continuity or security.
From discovery to full deployment
Corporate IT and production floor replaced
SOC & NOC monitoring live at go-live
Of ongoing management and support
For manufacturers, network infrastructure is more than an IT necessity. It connects business systems, supports production equipment, and helps keep operations moving.
When a global manufacturing company prepared to implement a new SAP system at one of its U.S. facilities, it faced a significant infrastructure challenge.
The facility needed to replace both its corporate IT network and its production floor network before the SAP system went live.
The deadline was fixed. Internal IT resources were already stretched thin. And the manufacturing environment couldn’t afford unnecessary disruptions.
Secureway IT stepped in to design, deploy, secure, and manage both networks within just two and a half months.
Four years later, Secureway IT continues to manage and monitor the environment.
The Challenge: Two Networks, One Deadline, Limited Resources
Manufacturing facilities operate in environments where network reliability directly affects productivity.
At the client’s U.S. facility, the upcoming SAP implementation required an infrastructure overhaul that extended far beyond traditional office connectivity.
The project involved two distinct environments:
Corporate IT Network
Wired and wireless infrastructure supporting employee workstations, business applications, communications, and everyday operations.
Production Floor Network
Wired infrastructure connecting manufacturing equipment and systems where network disruptions could affect production.
Both environments needed to be redesigned and replaced before the SAP rollout.
Complicating matters, the manufacturer’s internal IT team was already managing several competing initiatives. Although the team understood the technical requirements, it lacked the additional engineering resources and time necessary to complete the project independently.
As the facility’s IT lead explained:
“Without enough manpower, there was no way we could have met our project deadlines.”
Facility IT Lead, Global Manufacturer
When asked what could have happened without outside assistance, the response was straightforward:
“The project could have failed!”
Facility IT Lead, Global Manufacturer
The challenge wasn’t simply purchasing and installing new networking equipment. The manufacturer needed an experienced technology partner capable of coordinating infrastructure modernization, manufacturing network requirements, cybersecurity, and an immovable implementation schedule.
The Solution: A Complete Network Transformation in 10 Weeks
Secureway IT was already engaged with the manufacturer at the organizational level, allowing the team to begin planning quickly.
Rather than immediately deploying equipment, Secureway IT started with remote discovery and infrastructure planning.
Working directly with the facility’s IT leadership, the team documented requirements, existing infrastructure, technical dependencies, and operational constraints.
This discovery process helped establish a clear implementation strategy before engineers began replacing the network infrastructure.
On-Site Engineering and Deployment
Once planning was complete, Secureway IT brought engineering resources and technicians on-site to execute the project.
The deployment included:
- Replacing the facility's corporate wired and wireless network infrastructure.
- Designing and implementing the production floor's wired network.
- Deploying Fortinet networking and security technology.
- Incorporating cybersecurity controls into the infrastructure design.
- Establishing Security Operations Center (SOC) and Network Operations Center (NOC) monitoring.
- Implementing Sophos email security.
- Preparing the completed environment to support the scheduled SAP rollout.
Having engineers and technicians physically present was especially valuable in an active manufacturing facility, where infrastructure changes require coordination with operational constraints.
When asked what stood out about Secureway IT’s approach, the facility’s IT lead highlighted one thing:
“Yeah, boots on the ground!”
Facility IT Lead, Global Manufacturer
From initial discovery through deployment, the entire network replacement was completed in approximately 10 weeks.
Bridging the Gap Between Corporate IT and Manufacturing Networks
One of the most important aspects of the project was Secureway IT’s ability to support both traditional business networking and production floor infrastructure.
Although these environments operate within the same facility, they have fundamentally different requirements.
Corporate networks typically prioritize
- Employee connectivity
- Application performance
- Secure communications
- Access to business systems
Manufacturing networks must also account for
- Equipment connectivity
- Operational reliability
- Production schedules
- The consequences of unexpected downtime
A brief interruption to office Wi-Fi might inconvenience employees. A similar interruption on the production floor can affect manufacturing output.
Secureway IT designed and deployed both environments using Fortinet technology, bringing corporate and production networking under a coordinated infrastructure and management strategy.
This approach gave the manufacturer a single technology partner responsible for the infrastructure supporting both business operations and manufacturing systems.
Cybersecurity Built Into the Network From Day One
Security wasn’t treated as something to address after the new network was operational.
Secureway IT incorporated cybersecurity planning into the initial network architecture, with ongoing monitoring included in the deployment strategy.
A staffed Security Operations Center (SOC) and Network Operations Center (NOC) began monitoring the environment the same day the new infrastructure went live.
Sophos email security provided an additional layer of protection for business communications.
By integrating network deployment and security operations from the beginning, the manufacturer avoided launching its new infrastructure without an established monitoring program.
The Results: An On-Time SAP Rollout and Four Years of Continued Support
The project delivered more than a replacement network. It provided the manufacturer with the infrastructure, security monitoring, and ongoing technical support needed to move forward with its business initiatives.
Key Project Outcomes
10 weeks to deployment
Secureway IT completed the corporate and production floor network replacement within the project's fixed implementation window.
SAP rollout completed on schedule
The new infrastructure was ready to support the manufacturer's planned SAP deployment without delaying the implementation timeline.
Two networks, one management strategy
Corporate IT and manufacturing network infrastructure were deployed and are managed by Secureway IT.
Security monitoring from day one
SOC and NOC monitoring became operational alongside the new network infrastructure.
Four years of ongoing management
Secureway IT continues to manage, monitor, report on, and improve the manufacturer's environment.
Long-Term Operational Improvements
The relationship didn’t end when the installation was complete.
Four years after deployment, Secureway IT continues to provide network management, security monitoring, and monthly reporting.
These reports give the manufacturer visibility into security performance and trends, with most tracked security metrics improving over the course of the engagement.
Multiple Secureway IT teams now support the account, helping the internal IT personnel regain the capacity to address projects and responsibilities that previously competed for limited resources.
For the facility’s IT lead, the benefits were personal as well as operational.
“We did a lot of work in 2.5 months. It felt great not to work seven days a week anymore.”
Facility IT Lead, Global Manufacturer
What Other Manufacturers Can Learn From This Project
This manufacturer’s experience illustrates a challenge familiar to many manufacturing IT leaders: major technology initiatives rarely arrive when internal teams have extra time and resources available.
ERP implementations, infrastructure upgrades, security improvements, and production requirements often compete for the same limited engineering capacity.
Three factors helped make this project successful.
Planning around operational requirements
Understanding the differences between corporate IT and manufacturing networks allowed Secureway IT to develop an implementation strategy suited to the facility’s needs.
Bringing in additional engineering capacity
Experienced on-site technicians and engineers helped the manufacturer meet its deadline without placing the entire deployment burden on its existing IT team.
Building security and ongoing management into the project
Integrating SOC and NOC monitoring into the original deployment created a foundation for continued network visibility, security management, and improvement.
When asked what advice he would offer another manufacturer considering Secureway IT, the facility’s IT lead had a simple recommendation:
“Give them a shot. They have a lot of talent, and they really know their stuff.”
Facility IT Lead, Global Manufacturer
Planning a Manufacturing Network Upgrade?
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Whether you’re preparing for an ERP implementation, replacing aging network infrastructure, or looking to improve cybersecurity across your manufacturing environment, the right technology partner can make a significant difference.
Secureway IT helps businesses plan, deploy, secure, and manage complex IT infrastructure, including corporate networks and production environments.
From initial network assessments and infrastructure design to ongoing SOC and NOC monitoring, our team helps organizations tackle demanding technology projects without losing sight of business operations.
Have a network modernization project or a deadline that can’t move? Contact Secureway IT to speak with a security specialist about your infrastructure requirements, implementation timeline, and next steps.