Case Study

IT Transformation:
Manufacturing Company, North Carolina

Called in to evaluate and turn around a struggling IT environment. What leadership had scoped as a 5-year roadmap was complete in 18 months.

Industry
Manufacturing
Timeline
18 Months
Engagement
End-to-End IT Transformation

Seven areas transformed. One engagement.

$5.8M
ERP Cost Avoided
Consultants quoted $6M for replacement. Assessment revealed process misuse, not a software problem.
9 hrs → 14+ days
Backup Retention
No cloud backup existed. Office 365 and critical data now fully covered.
20+ → 5
Server Footprint
Consolidated from 4 unsupported hosts. All running supported hardware.
25%
Faster Project Delivery
IT governance and roadmap clarity introduced. Structured planning replaced ad-hoc prioritization.
First-ever
Help Desk KPIs
No metrics existed before. Peak demand days and times identified and staffed.
Zero → Tested
Disaster Recovery Plan
Built from scratch. Validated through tabletop exercise.
50+ cameras
Surveillance Unified
6 fragmented DVR systems consolidated. Standardized on Everon / ADT platform.

Years of deferred investment had created serious exposure.

Called in to evaluate and turn around a struggling IT environment for a manufacturing company in North Carolina, Keith led the end-to-end transformation of their technology infrastructure.

Years of deferred investment had left the organization with outdated systems, no meaningful management support for IT initiatives, and a relationship between IT and the rest of the business that had largely broken down.

Technical Debt. Years of deferred investment in hardware, software, and process had created serious risk exposure across the environment.
No Management Support. IT initiatives had lost leadership buy-in, making prioritization and funding for meaningful improvements nearly impossible.
Fractured Relationships. The breakdown between IT and the rest of the organization had eroded user trust and created friction in daily operations.

$5.8M saved by asking the right question first.

The ERP system had a reputation as a poor fit. External consultants had quoted $6M to replace it with larger platforms. A structured assessment found a different story: the problems came from internal process misuse, not from limitations of the software itself.

By re-aligning warehouse, shipping, receiving, and materials processes to industry best practices, the existing system was able to handle what the business actually needed. The ERP stayed. The $5.8M didn't go out the door.

1

Process Re-alignment

Re-aligned warehouse, shipping, receiving, and materials processes to industry best practices.

2

Cloud Testing

Prepared and tested an upgrade in a cloud-hosted environment before committing.

3

Server Migration

Migrated three ERP-related physical servers into the cloud as part of the upgrade.

Nine-hour backup window. No cloud coverage. No one knew.

The company did not fully understand how exposed they were. Backups were only retained for nine hours, and nothing was being backed up for critical cloud services including Office 365. A ransomware attack or a single hardware failure could have resulted in unrecoverable data loss with no practical path to restore operations.

A quick win was deployed immediately while the permanent solution was architected: portable storage to extend the retention window. The permanent solution addressed every gap.

Full backups on Sundays, daily differentials — 14+ days of retention
Office 365 backup introduced: SharePoint, Teams, OneDrive, and Exchange mailboxes
Virtual server backups (Hyper-V) with replication to a disaster recovery site
Wasabi cloud storage integrated for offsite, immutable backups

From 20+ servers on unsupported hardware to 5 on a modern stack.

Most of the network equipment was unsupported by manufacturers with no active support contracts. In the event of hardware failure, prolonged downtime was highly likely. The consolidation removed that risk, simplified the environment, and positioned the organization to shift additional workloads to the cloud.

Server Consolidation

Reduced server footprint from 20+ servers across 4 hosts to 5 servers across 3 hosts, all on supported hardware.

Network Modernization

Replaced aging switches, routers, and firewalls with Fortinet gear to improve visibility, throughput, and reliability.

Redundancy Built In

Implemented dual WAN firewalls with auto-failover so that a single connection failure no longer stops the business.

Built from scratch. Tested before it was ever needed.

The absence of a documented Disaster Recovery Plan was a major gap. A formal Disaster Recovery and Incident Response Plan was developed in collaboration with an MSP — distributed to every department that needed it, then tested through a tabletop exercise before it was ever needed in production.

A regular review cycle was established to keep the plan current as the environment and the business continue to evolve.

Documentation. Built the full DR and Incident Response documentation and distributed it to every department that needed it.
Validation. Ran a tabletop exercise with the team to test the plan against real scenarios before it was ever needed in production.
Ongoing Maintenance. Set up a regular review cycle to keep the plan current as the environment and business continue to change.

The team had no metrics, no tools, and no trust from the business.

The IT team had been cut off from the rest of the company. They lacked real tools, had no metrics to show their performance, and had no way to demonstrate value. Frustration had built up on both sides.

The goal was to get IT reconnected to the business, give the team structure, and make performance visible. Ticket trend analysis identified peak demand days and times, enabling smarter staffing decisions. Leadership received the first-ever KPI report on help desk performance.

Rebuilt relationships between IT and business units damaged by prior leadership
Introduced KPIs for the first time — leadership now had visibility into help desk performance
Ticket trend analysis identified peak demand periods, enabling data-driven staffing
Replaced legacy tools with NinjaOne and Kaseya — shifted the team from reactive to structured

Aging file server replaced with a modern collaboration platform.

The organization was relying on an on-premise file server that was rapidly running out of storage and becoming unreliable. On-premise file shares and collaboration data were migrated to SharePoint Online, enabling mobile and remote-friendly access through Microsoft 365 integration. Better performance, better user experience, and long-term scalability.

50+ cameras across 6 fragmented systems — unified.

The surveillance system was fragmented across multiple NVR and DVR units with many cameras malfunctioning. HR and leadership had no reliable way to retrieve footage for safety investigations. Failing cameras were replaced immediately as a quick win, then the full system was standardized on a unified Everon / ADT IP-based platform with improved camera placement and easy footage retrieval.

"When I arrived: nine-hour backup retention, 20+ servers on unsupported hardware, and consultants recommending a costly ERP replacement. 18 months later: 14+ day backup retention with offsite copies, server footprint cut from 20+ to 5, a tested DR plan in place, collaboration moved to the cloud, and the ERP intact because the real problem was how the team used it. The issues were real. Most just were not where anyone expected."
18 months
to complete what leadership had scoped as a 5-year roadmap

Key platforms and tools deployed in this engagement.

Backup & DR
Datto, Unitrends, Wasabi
Cloud & Collaboration
Microsoft 365 (SharePoint, Teams, OneDrive, Exchange)
Help Desk
NinjaOne, Kaseya
Virtualization
Hyper-V
Networking & Security
Fortinet (firewalls, switches, wireless), dual WAN failover
Surveillance
Everon / ADT
Cloud Migration
SharePoint Online, Microsoft Azure
Identity Management
Active Directory, Azure AD
IT Governance
Structured IT discovery, roadmap planning, KPI frameworks

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