Achieving 5 Years of Zero Downtime in Heavy Manufacturing

Our client operates a 24/7 automated manufacturing plant producing critical components for the automotive sector. Their legacy IT infrastructure was closely tied to their Operational Technology (OT) network. A minor server failure on the IT side would cascade, halting the robotic assembly lines and costing roughly RM 50,000 per hour in lost productivity and supply chain penalties.

PC Risks implemented a true Zero Downtime Architecture. We separated the IT and OT networks using strict micro-segmentation, ensuring that a failure or breach in one could not affect the other. We then deployed a high-availability (HA) cluster of on-premise servers right at the edge of the factory floor.

Using active-active replication, every transaction is instantly mirrored. If the primary hardware node fails, the secondary node assumes control in under 2.5 seconds—a delay so small the robotic PLCs do not even register a network drop.

The new infrastructure has been running for 5 consecutive years without a single second of unplanned downtime. The client successfully scaled their production output by 40% using the same footprint, fully confident that their IT backbone could support the load.