Legacy ERP System Redevelopment
Legacy ERP System Redevelopment for an Industrial Equipment Manufacturer
Legacy ERP System Redevelopment for an Industrial Equipment Manufacturer
Legacy ERP System Redevelopment for an Industrial Equipment Manufacturer
When a leading German industrial equipment manufacturer found their 70-year legacy hampering growth, they turned to Brightgrove for a solution.
When a leading German industrial equipment manufacturer found their 70-year legacy hampering growth, they turned to Brightgrove for a solution.
When a leading German industrial equipment manufacturer found their 70-year legacy hampering growth, they turned to Brightgrove for a solution.
REST API
Cloud
Manufacturing
Legacy ERP System Redevelopment
Legacy ERP System Redevelopment
Legacy ERP System Redevelopment
Client profile
Client profile
Client profile
When a leading German industrial equipment manufacturer found their 70-year legacy hampering growth, they turned to Brightgrove for a solution. Their outdated WinForms and MS SQL ERP system had become a significant operational bottleneck, limiting efficiency and scalability. This case study details how Brightgrove transformed their legacy system while maintaining business continuity, resulting in 60% faster data processing and 30% reduced IT costs.
For over seven decades, this Bochum-based manufacturer has built a reputation for engineering excellence in magnetic drive technology. Their pumps, valves, and agitators serve critical applications in chemical processing, pharmaceuticals, oil & gas, and water treatment facilities across Europe and Asia. Known for precision engineering and product longevity, the company had outgrown its technological foundation as it expanded into new markets.
When a leading German industrial equipment manufacturer found their 70-year legacy hampering growth, they turned to Brightgrove for a solution. Their outdated WinForms and MS SQL ERP system had become a significant operational bottleneck, limiting efficiency and scalability. This case study details how Brightgrove transformed their legacy system while maintaining business continuity, resulting in 60% faster data processing and 30% reduced IT costs.
For over seven decades, this Bochum-based manufacturer has built a reputation for engineering excellence in magnetic drive technology. Their pumps, valves, and agitators serve critical applications in chemical processing, pharmaceuticals, oil & gas, and water treatment facilities across Europe and Asia. Known for precision engineering and product longevity, the company had outgrown its technological foundation as it expanded into new markets.
When a leading German industrial equipment manufacturer found their 70-year legacy hampering growth, they turned to Brightgrove for a solution. Their outdated WinForms and MS SQL ERP system had become a significant operational bottleneck, limiting efficiency and scalability. This case study details how Brightgrove transformed their legacy system while maintaining business continuity, resulting in 60% faster data processing and 30% reduced IT costs.
For over seven decades, this Bochum-based manufacturer has built a reputation for engineering excellence in magnetic drive technology. Their pumps, valves, and agitators serve critical applications in chemical processing, pharmaceuticals, oil & gas, and water treatment facilities across Europe and Asia. Known for precision engineering and product longevity, the company had outgrown its technological foundation as it expanded into new markets.
Initial state. The challenge landscape
Initial state. The challenge landscape
Initial state. The challenge landscape
The manufacturer’s ERP system had been developed and expanded over decades, resulting in a patchwork of technologies that were increasingly difficult to maintain.
The manufacturer’s ERP system had been developed and expanded over decades, resulting in a patchwork of technologies that were increasingly difficult to maintain.
Legacy Technology Stack
• Frontend: WinForms-based client application
• Backend: .NET Framework (outdated version)
• Database: Microsoft SQL Server 2008
• Deployment: On-premises servers with limited redundancy
• Integration: Primarily file-based data exchange, minimal API capabilities
• Security: Basic authentication, limited audit trails
Business Process Bottlenecks
• The technical limitations directly impacted daily operations, creating significant inefficiencies across core business functions:
• Order Processing. 3-4 days average cycle time due to manual data entry and verification steps
• Inventory Management. Weekly batch updates creating visibility gaps and production planning challenges
• Supply Chain. Limited vendor integration requiring duplicate data entry across systems
• Reporting. 8-10 hours of staff time per week spent on manual Excel-based reporting
• Customer Service. Limited visibility into order status and manufacturing progress
Legacy Technology Stack
• Frontend: WinForms-based client application
• Backend: .NET Framework (outdated version)
• Database: Microsoft SQL Server 2008
• Deployment: On-premises servers with limited redundancy
• Integration: Primarily file-based data exchange, minimal API capabilities
• Security: Basic authentication, limited audit trails
Business Process Bottlenecks
• The technical limitations directly impacted daily operations, creating significant inefficiencies across core business functions:
• Order Processing. 3-4 days average cycle time due to manual data entry and verification steps
• Inventory Management. Weekly batch updates creating visibility gaps and production planning challenges
• Supply Chain. Limited vendor integration requiring duplicate data entry across systems
• Reporting. 8-10 hours of staff time per week spent on manual Excel-based reporting
• Customer Service. Limited visibility into order status and manufacturing progress
Legacy Technology Stack
• Frontend: WinForms-based client application
• Backend: .NET Framework (outdated version)
• Database: Microsoft SQL Server 2008
• Deployment: On-premises servers with limited redundancy
• Integration: Primarily file-based data exchange, minimal API capabilities
• Security: Basic authentication, limited audit trails
Business Process Bottlenecks
• The technical limitations directly impacted daily operations, creating significant inefficiencies across core business functions:
• Order Processing. 3-4 days average cycle time due to manual data entry and verification steps
• Inventory Management. Weekly batch updates creating visibility gaps and production planning challenges
• Supply Chain. Limited vendor integration requiring duplicate data entry across systems
• Reporting. 8-10 hours of staff time per week spent on manual Excel-based reporting
• Customer Service. Limited visibility into order status and manufacturing progress
Growing Organizational Risk
Beyond day-to-day inefficiencies, the legacy system presented strategic risks. As transaction volumes grew, system performance degraded significantly. The outdated frameworks created security vulnerabilities that could no longer be patched. Even minor updates required specialized WinForms knowledge, which had become increasingly scarce in the German IT market.
Most concerning was the business continuity risk—system failures directly threatened production operations. The legacy architecture also prevented integration with emerging industrial IoT sensors and data analytics platforms, hindering the company’s digital transformation ambitions.
Growing Organizational Risk
Beyond day-to-day inefficiencies, the legacy system presented strategic risks. As transaction volumes grew, system performance degraded significantly. The outdated frameworks created security vulnerabilities that could no longer be patched. Even minor updates required specialized WinForms knowledge, which had become increasingly scarce in the German IT market.
Most concerning was the business continuity risk—system failures directly threatened production operations. The legacy architecture also prevented integration with emerging industrial IoT sensors and data analytics platforms, hindering the company’s digital transformation ambitions.
The transformation journey
The transformation journey
The transformation journey
Rather than pursuing a risky “big bang” replacement, Brightgrove implemented a four-phase transformation approach designed to minimize disruption while systematically addressing technical debt.
Phase 1: | Phase 2: | Phase 3: | Phase 4: |
|---|---|---|---|
Assessment & Planning (6 weeks) | Architecture Modernization (10 weeks) | Incremental Implementation (24 weeks) | Optimization & Extension (8 weeks) |
• Comprehensive business process mapping • Technical debt inventory • Migration risk assessment • Stakeholder alignment workshops | • Database optimization and schema refinement • Core business logic identification and isolation • API layer development for future extensibility • Security architecture redesign | • Module-by-module refactoring and migration • Parallel testing environment • Blue/green deployment methodology • User acceptance testing and refinement | • Performance tuning • Advanced reporting implementation • IoT sensor integration framework • User training and change management |
Rather than pursuing a risky “big bang” replacement, Brightgrove implemented a four-phase transformation approach designed to minimize disruption while systematically addressing technical debt.
Phase 1: | Phase 2: | Phase 3: | Phase 4: |
|---|---|---|---|
Assessment & Planning (6 weeks) | Architecture Modernization (10 weeks) | Incremental Implementation (24 weeks) | Optimization & Extension (8 weeks) |
• Comprehensive business process mapping • Technical debt inventory • Migration risk assessment • Stakeholder alignment workshops | • Database optimization and schema refinement • Core business logic identification and isolation • API layer development for future extensibility • Security architecture redesign | • Module-by-module refactoring and migration • Parallel testing environment • Blue/green deployment methodology • User acceptance testing and refinement | • Performance tuning • Advanced reporting implementation • IoT sensor integration framework • User training and change management |
Rather than pursuing a risky “big bang” replacement, Brightgrove implemented a four-phase transformation approach designed to minimize disruption while systematically addressing technical debt.
Phase 1: | Phase 2: | Phase 3: | Phase 4: |
|---|---|---|---|
Assessment & Planning (6 weeks) | Architecture Modernization (10 weeks) | Incremental Implementation (24 weeks) | Optimization & Extension (8 weeks) |
• Comprehensive business process mapping • Technical debt inventory • Migration risk assessment • Stakeholder alignment workshops | • Database optimization and schema refinement • Core business logic identification and isolation • API layer development for future extensibility • Security architecture redesign | • Module-by-module refactoring and migration • Parallel testing environment • Blue/green deployment methodology • User acceptance testing and refinement | • Performance tuning • Advanced reporting implementation • IoT sensor integration framework • User training and change management |
Technology stack evolution
Technology stack evolution
Technology stack evolution
The modernization preserved familiar interface elements while transforming the underlying technology:
Component | Legacy State | Modernized State | Strategic Benefit |
|---|---|---|---|
Frontend | WinForms | WinForms with modern UI controls | Familiar interface with improved usability |
Backend | .NET Framework (outdated) | Modern .NET with C# | Enhanced performance, security, maintainability |
Database | MS SQL 2008 | MS SQL 2019 | Improved query performance, advanced features |
Security | Basic authentication | RBAC + OAuth integration | GDPR compliance, granular access control |
Integration | File-based | REST API architecture | Easy third-party integration, IoT readiness |
Deployment | On-premises only | Hybrid (on-prem + cloud backup) | Improved business сontinuity, disaster recovery |
The modernization preserved familiar interface elements while transforming the underlying technology:
Component | Legacy State | Modernized State | Strategic Benefit |
|---|---|---|---|
Frontend | WinForms | WinForms with modern UI controls | Familiar interface with improved usability |
Backend | .NET Framework (outdated) | Modern .NET with C# | Enhanced performance, security, maintainability |
Database | MS SQL 2008 | MS SQL 2019 | Improved query performance, advanced features |
Security | Basic authentication | RBAC + OAuth integration | GDPR compliance, granular access control |
Integration | File-based | REST API architecture | Easy third-party integration, IoT readiness |
Deployment | On-premises only | Hybrid (on-prem + cloud backup) | Improved business сontinuity, disaster recovery |
The modernization preserved familiar interface elements while transforming the underlying technology:
Component | Legacy State | Modernized State | Strategic Benefit |
|---|---|---|---|
Frontend | WinForms | WinForms with modern UI controls | Familiar interface with improved usability |
Backend | .NET Framework (outdated) | Modern .NET with C# | Enhanced performance, security, maintainability |
Database | MS SQL 2008 | MS SQL 2019 | Improved query performance, advanced features |
Security | Basic authentication | RBAC + OAuth integration | GDPR compliance, granular access control |
Integration | File-based | REST API architecture | Easy third-party integration, IoT readiness |
Deployment | On-premises only | Hybrid (on-prem + cloud backup) | Improved business сontinuity, disaster recovery |
Implementation deep dive
Implementation deep dive
Implementation deep dive
The technical implementation addressed multiple dimensions simultaneously:
• Database Optimization. Restructured database schema, implemented proper indexing, and query optimization resulting in 60% faster transaction processing
• Code Refactoring. Extracted business logic from UI layer, implemented proper design patterns, reduced code complexity by 40%
• Security Enhancements. Implemented encryption for sensitive data, comprehensive audit logging, and integration with Active Directory
• UI/UX Improvements. Redesigned critical workflows while maintaining familiar interface elements to minimize training requirements
• Integration Layer. Developed comprehensive API framework enabling future IoT integration and third-party connectivity
Throughout implementation, Brightgrove’s specialized team of .NET engineers with WinForms expertise provided the rare combination of skills needed to bridge legacy and modern technologies successfully.
The technical implementation addressed multiple dimensions simultaneously:
• Database Optimization. Restructured database schema, implemented proper indexing, and query optimization resulting in 60% faster transaction processing
• Code Refactoring. Extracted business logic from UI layer, implemented proper design patterns, reduced code complexity by 40%
• Security Enhancements. Implemented encryption for sensitive data, comprehensive audit logging, and integration with Active Directory
• UI/UX Improvements. Redesigned critical workflows while maintaining familiar interface elements to minimize training requirements
• Integration Layer. Developed comprehensive API framework enabling future IoT integration and third-party connectivity
Throughout implementation, Brightgrove’s specialized team of .NET engineers with WinForms expertise provided the rare combination of skills needed to bridge legacy and modern technologies successfully.
The technical implementation addressed multiple dimensions simultaneously:
• Database Optimization. Restructured database schema, implemented proper indexing, and query optimization resulting in 60% faster transaction processing
• Code Refactoring. Extracted business logic from UI layer, implemented proper design patterns, reduced code complexity by 40%
• Security Enhancements. Implemented encryption for sensitive data, comprehensive audit logging, and integration with Active Directory
• UI/UX Improvements. Redesigned critical workflows while maintaining familiar interface elements to minimize training requirements
• Integration Layer. Developed comprehensive API framework enabling future IoT integration and third-party connectivity
Throughout implementation, Brightgrove’s specialized team of .NET engineers with WinForms expertise provided the rare combination of skills needed to bridge legacy and modern technologies successfully.
Results and achievements
Results and achievements
Results and achievements
While quantitative improvements were significant, the qualitative benefits transformed how the company operated:
While quantitative improvements were significant, the qualitative benefits transformed how the company operated:
Enhanced Decision Making
Enhanced Decision Making
Enhanced Decision Making
Real-time visibility into operations enabling data-driven decisions
Real-time visibility into operations enabling data-driven decisions
Real-time visibility into operations enabling data-driven decisions
Improved User Satisfaction
Improved User Satisfaction
Improved User Satisfaction
Modern interface with intuitive workflows reduced training needs
Modern interface with intuitive workflows reduced training needs
Modern interface with intuitive workflows reduced training needs
Reduced Technical Risk
Reduced Technical Risk
Reduced Technical Risk
Elimination of unsupported technologies and security vulnerabilities
Elimination of unsupported technologies and security vulnerabilities
Elimination of unsupported technologies and security vulnerabilities
Future-Ready Platform
Future-Ready Platform
Architecture supports IoT integration, AI analytics, and cloud migration path
Architecture supports IoT integration, AI analytics, and cloud migration path
Competitive Advantage
Competitive Advantage
Competitive Advantage
Faster order processing and improved accuracy enhancing customer satisfaction
Faster order processing and improved accuracy enhancing customer satisfaction
Faster order processing and improved accuracy enhancing customer satisfaction
Conclusion
Conclusion
Conclusion
This ERP modernization project demonstrates the strategic value of addressing technical debt while enabling future innovation. By taking a methodical, business-focused approach to legacy system transformation, Brightgrove delivered significant operational improvements while minimizing disruption to manufacturing operations.
The modernized ERP now serves as a foundation for digital transformation, enabling real-time manufacturing insights, improved supply chain visibility, and long-term operational efficiency in an increasingly competitive global market. The project stands as a testament to the power of strategic technology modernization to not just address current challenges but to create pathways for future growth and innovation.
This ERP modernization project demonstrates the strategic value of addressing technical debt while enabling future innovation. By taking a methodical, business-focused approach to legacy system transformation, Brightgrove delivered significant operational improvements while minimizing disruption to manufacturing operations.
The modernized ERP now serves as a foundation for digital transformation, enabling real-time manufacturing insights, improved supply chain visibility, and long-term operational efficiency in an increasingly competitive global market. The project stands as a testament to the power of strategic technology modernization to not just address current challenges but to create pathways for future growth and innovation.
This ERP modernization project demonstrates the strategic value of addressing technical debt while enabling future innovation. By taking a methodical, business-focused approach to legacy system transformation, Brightgrove delivered significant operational improvements while minimizing disruption to manufacturing operations.
The modernized ERP now serves as a foundation for digital transformation, enabling real-time manufacturing insights, improved supply chain visibility, and long-term operational efficiency in an increasingly competitive global market. The project stands as a testament to the power of strategic technology modernization to not just address current challenges but to create pathways for future growth and innovation.
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