Legacy System Modernisation for Manufacturing

We run your old and new systems in parallel. Data syncs bidirectionally during the transition period, so staff uses the legacy system while we validate the new platform behind the scenes. Once all modules are proven stable and data integrity is confirmed, we cut over to the new system during a planned maintenance window. This approach typically takes 6-12 weeks depending on system complexity, and you keep manufacturing running throughout.

We refactor where possible. We analyze your monolithic code, identify service boundaries (inventory, scheduling, costing, quality), extract them incrementally, and rebuild as independent microservices. This keeps your business logic and data intact while modernizing the structure. Full rebuilds are rare and more expensive. Refactoring is typically 40-60% faster and much lower risk.

Data integrity is our priority. We perform full audits before, during, and after migration. Every inventory record, production order, and transaction is validated against your original system. We run reconciliation reports line-by-line and flag any discrepancies before cutover. Your data stays yours and stays correct.

Once refactored to microservices, each module exposes clean APIs. Your production management system, IoT sensors, or supply chain software connects via these APIs rather than through the monolith's brittle integration points. We document these APIs and provide integration support. Adding new tools becomes straightforward, and you are not locked into one vendor.

Our team includes engineers who have migrated legacy manufacturing platforms, ERP specialists, and cloud architects. We understand production workflows, inventory processes, and the business impact of downtime. We are not generic software contractors. We take time to learn your manufacturing process before proposing solutions, so recommendations match your actual operations, not a template.

Cost depends on system size, architecture complexity, and integration scope. A typical mid-sized manufacturing platform costs between £60k-£200k to modernise. We start with a discovery phase where we audit your system, estimate effort, and propose a phased roadmap with clear milestones. You see pricing before committing to a full project. We also offer nearshore delivery across the UK, Spain, and Ukraine, which gives cost flexibility without sacrificing quality or timezone alignment.