Upgrading Manufacturing Plant Custom Application Technology Stack

Driving Efficiency: A Manufacturing Legacy Application Modernization Case Study

Background

A large automotive plant operator relied on a custom application framework that was integral to their core operations. This critical application, originally developed using JDK8 and JBoss4 and leveraging an Oracle database, had received periodic maintenance but saw its last major technological update in late 2020/early 2021. Recognizing the pressing need to enhance performance, security, and long-term maintainability, the client partnered with Performance One Data Solutions, a division of Ross Group Inc., in 2024 to embark on a vital Manufacturing Legacy Application Modernization effort to fully upgrade the outdated technology stack.

Objectives

The primary goals of the project were:

1. Upgrade the Custom Application Framework from JDK8 to JDK21.
2. Upgrade the jQuery integration to release 3.7.1.
3. Upgrade the application to run on Wildfly 30 from Wildfly 11.
4. Migrate the database backend from Oracle 12 to Microsoft SQL Server 2020.

Challenges and Solutions

Framework and Database Migration:

• Challenge: The application framework was vetted against Microsoft SQL Server but was not deployed in a major application.
• Solution: Performance One refactored the framework to conform to Java 9+ standards and regression-tested it against Microsoft SQL Server 2020.

Application Refactoring:

• Challenge: Refactoring the client application to compile and run using the new tech stack.
• Solution: Performance One took a copy of the client application and refactored it to compile and launch using JDK21, Wildfly 30, and Microsoft SQL Server.

Data Migration:

• Challenge: Migrating data from Oracle to Microsoft SQL Server.
• Solution: Performance One provided migrated data and created installation scripts to upgrade the client’s Microsoft SQL Server

Report Conversion:

• Challenge: Converting BIRT and Crystal reports against Microsoft SQL Server.
• Solution: Performance One converted the reports and ensured they worked with Microsoft SQL Server

Project Timeline

Initial Milestones:

• 1. Complete Framework upgrade to JDK21/Wildfly 30.
  2. Provide migrated data from Oracle to Microsoft SQL Server.
  3. Regression test the application framework against Microsoft SQL Server 2020.
  4. Refactor the client’s application to compile and launch using the new tech stack.
  5. Create installation data script for Microsoft SQL Server compliance.
  6. Regression test the application installation processes.
  7. Make recommendations for unused application features.
  8. Validate and upgrade application code.

Additional Tasks

• Database Procedures Conversion: Performance One converted the client’s database procedures, functions, and views to Microsoft SQL Server.
• Report Migrations: Ongoing conversion of BIRT and Crystal report development.
• Application Enhancements: Upgrading client’s application screens for jQuery 3.7.1, file attachment uploads, and integration with scanner devices using web sockets.
• Server Maintenance: Wildfly server maintenance, release builds, and deployment handling, with a transition plan for client resources post-go-live.

Conclusion

Performance One Data Solutions partnered with the client to upgrade the technology stack, ensuring improved performance and maintainability. The collaboration between Performance One and the client team demonstrated effective problem-solving and adaptability, setting a strong foundation for future upgrades and enhancements.

Ready to Modernize Your Legacy Systems?

At Performance One Data Solutions, we specialize in transforming outdated technology into agile, future-proof platforms tailored to your business needs. Whether you’re facing performance bottlenecks, security concerns, or scalability challenges, our team is ready to help you modernize with confidence.

👉 Let’s talk about your next upgrade.
Contact us today to schedule a free consultation and discover how we can help you unlock the full potential of your technology stack.

📞 Call: (888) 692-3282
📧 Email: info@performanceonedatasolutions.com