Key Highlights
- OptiSol helped a global manufacturing firm modernize its legacy systems by migrating from a rigid monolithic setup to a scalable microservices architecture using the Gen AI-driven iBEAM accelerator within just 8 weeks.
- The legacy architecture caused integration delays, slow feature rollouts, and rising infrastructure costs. These challenges stemmed from tightly coupled components and limited flexibility in scaling or adapting to changing business needs.
- We delivered a rapid, end-to-end modernization in just eight weeks by leveraging our proprietary iBEAM accelerator for blueprinting, extraction, automated testing, and phased microservices deployment with zero disruption.
- Post-modernization, the client experienced improved scalability, reduced infrastructure costs, and faster go-to-market timelines for product launches, enabling better responsiveness to customer demands and competitive shifts.
Problem Statement
01
Legacy Complexity: The client’s existing monolithic system created major hurdles when integrating with microservices, often causing data inconsistencies, duplicate processing, and operational disruptions during transitional phases and live deployments.
02
Agility Constraints: The monolithic architecture made it difficult to introduce new features quickly. This slowed down the client’s ability to respond to market demands and deliver timely updates, especially during high-demand periods.
03
High Costs: Managing the legacy system involved significant infrastructure and operational expenses. As user demand grew, the cost of scaling and maintaining the monolithic environment became increasingly unsustainable and inefficient.
04
Low Efficiency: Due to tightly coupled code and lack of modularity, small changes triggered extensive regression efforts. This slowed down development cycles and limited the overall performance and scalability of the application.
Solution Overview
01
Accelerated Engagement: OptiSol partnered with the client to lead a focused and time-bound modernization initiative using its proprietary iBEAM accelerator to ensure rapid transformation with minimal disruption.
02
AI-Driven Blueprinting: We used Gen AI tools to analyze the existing application’s structure and auto-generate a detailed microservices blueprint based on code behavior, domain separation, and service boundaries.
03
Microservices Extraction: Our team applied static code analysis and dependency tracking to identify candidate services. We restructured and separated the logic while optimizing CI/CD pipelines for efficient development and deployment workflows.
04
Quality Assurance: Automated testing was integrated at multiple stages, supported by clear and consistent OpenAPI documentation for every service. This improved traceability, reduced bugs, and ensured compliance with modern coding standards.
05
Controlled Deployment: We built a production-like staging environment for testing. With observability tools in place, microservices were deployed in phases to minimize risk, reduce downtime, and maintain business continuity post-launch.
Business Impact
About The Project
This success story showcases how OptiSol supported a major manufacturing firm in transforming its digital architecture by replacing a legacy monolith with a modern microservices system. The transformation was completed in just 8 weeks using OptiSol’s Gen AI iBEAM accelerator. By automating blueprint generation, optimizing CI/CD pipelines, and deploying with minimal downtime, the client gained significant cost savings and increased agility. The modernization initiative strengthened their competitive edge through improved performance, faster delivery, and scalable operations.
FAQs:
Why should a manufacturing firm modernize from monolithic to microservices architecture?
Modernizing to microservices enhances scalability, reduces infrastructure costs, and improves development speed. It allows faster feature releases, easier maintenance, and better alignment with evolving business needs in dynamic manufacturing environments.
How does Gen AI accelerate app modernization in legacy environments?
Gen AI analyzes code structure, auto-generates service blueprints, and streamlines dependency mapping. This reduces manual effort, accelerates planning, and ensures faster, more accurate transitions to modern architectures with minimal disruption.
What is OptiSol’s iBEAM accelerator, and how does it work?
iBEAM is a proprietary modernization framework that combines Gen AI automation with engineering best practices. It enables rapid legacy assessment, blueprint creation, CI/CD optimization, and phased microservices deployment for faster transformation.
How is downtime avoided during modernization or deployment?
Downtime is minimized using a production-like staging environment, phased rollouts, and observability tools. Real-time monitoring and controlled deployment ensure business continuity and reduce the risk of disruption during critical transition stages.
How are quality assurance and testing handled in a microservices migration?
Automated testing is integrated at each stage of the pipeline. Every service includes OpenAPI documentation, enabling traceability, faster debugging, and adherence to coding standards, ensuring reliable performance post-migration.
Testimonials of Our Happy Clients
Ken Kisner
Global Head of Digital R&D
My experience has been incredibly positive. They were incredibly easy to work with, even with changing requirements.
They are incredibly competitive, but are only a fraction of the cost of US companies.
They are definitely the most professional of the foreign companies that we were looking into.
Nyswyn K.
Director of Software Development
Our journey with OptiSol has been nothing short of remarkable. For over 7 years, we have partnered with them on our digital transformation, and the results have been truly transformative.
Over the years, we have come to trust OptiSol Business Solutions as a reliable and strategic partner.
Al Bagiro
CTO, Auto Insurance Company
The AI engine was completed on time and trained to 90% accuracy. Their eagerness to learn new knowledge impressed us.
Their team is large to handle multiple projects at once, and likes to resolve challenges as well as learn new things. They also welcome regular communications, and of course, needless to say, develop everything in sprints.
Dan Talken
Founder, CEO, & CTO, My Equipment Library, LLC
OptiSol Business Solutions has shown youthful skill and dedication to the projects. Moreover, they have been quick to implement their solutions without sacrificing the quality of each platform.
We’re constantly impressed with their speed and quality of the development that they achieve on a consistent basis.
Dr. A.K Pradeep
CEO MachineVantage
Exceptional Collaboration and Expertise - A Top-Notch Partner for AI, ML, and Digital Applications.
I have had the privilege of working with an exceptional team of professionals from India on numerous AI, ML, and digital application projects. Their expertise in these domains is remarkable, and they consistently impressed us with their knowledge, resources, and innovative approach.
Rick Tigges
CFO, Bemodo
They are very responsive and able to shift focus quickly as we have needed it for business reasons.
OptiSol Business Solutions has been great at documenting the timeline of the project. They were very responsive and were able to shift focus quickly, as well. They discuss what they’re working on without any issues. So far, there’s no need to improve their service.
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