A precision manufacturer rebuilds its plant network and separates OT from IT
Unplanned line stoppages traced back to a flat network where office PCs and CNC controllers shared one broadcast domain. CloudSprint redesigned and rebuilt the network across three sites.
Sample case study. Details are representative and will be replaced with a real engagement.
The challenge
The manufacturer had one flat network across the main plant. CNC controllers, quality stations, the ERP server, and front office PCs all shared it. A malware infection on a shipping clerk’s laptop had already stopped a line for a shift. Warehouse Wi-Fi dropped whenever forklifts moved between racking aisles.
What CloudSprint did
Survey. We walked both plants and the warehouse, ran a predictive and on-site Wi-Fi survey, and interviewed line leads about where and when connectivity failed.
Design. The new architecture separated OT, IT, guest, and vendor traffic into segmented VLANs with a firewall between them. Industrial-rated switches went on the plant floor. SD-WAN linked all three sites with dual ISPs at each.
Build. Cabling and hardware went in during planned downtime and shift changes over eight weekends. Each phase had a rollback plan and none were needed.
Hand over. As-built diagrams, labeled patch panels, and a documented change process were delivered to the internal IT lead, and the network moved under CloudSprint monitoring.
The result
Twelve months later there have been no network-related production stoppages. Warehouse scanners hold their connection through every aisle. Vendor remote access now goes through a controlled gateway instead of an open port.
“The old network was a mystery to everyone including the people who built it. Now we have a diagram on the wall and a team that answers when we call.”
— Director of Operations, South Bay precision manufacturer
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