In manufacturing, downtime means missed dollar signs. The cost of a single hour of downtime can range from thousands to upwards of half a million dollars. So, when a patching process goes rogue, it’s not just an inconvenience—it’s a serious threat to revenue and even jobs.
One of our manufacturing clients was facing this exact scenario. Their patching process was causing unplanned downtime, driving production costs up and revenue down. With limited resources, their internal team couldn’t find a solution.
We stepped in and helped fix the problem, streamlining their entire patching system. Not only did we ensure patching windows avoided production hours, but we also gave their IT department full visibility into every patch. Now they know exactly what’s being updated and when, allowing them to plan effectively, minimize downtime, and maximize profits.
Why Did Server Patching Cost a Fortune?
In manufacturing, downtime isn’t just an inconvenience—it’s a major expense. For this client, server patching was causing:
- Significant Backlogs: Important updates hadn’t been applied for months, leaving systems vulnerable.
- Unexpected Reboots: Servers restarted unpredictably during the week, disrupting production.
- High Costs: Every unplanned restart put production on hold, leading to financial losses.
Even with scheduled update policies in place, the backlog of patches overwhelmed their system. When a server reboot unexpectedly halted production midweek, it became clear they needed a better solution.
How to Streamline Server Patching Without Causing Downtime
The challenge wasn’t just outdated servers—it was a patching system problem. Here’s how we addressed it:
- Custom PowerShell Script: We developed a script that:
- Scanned servers for pending updates.
- Installed updates in an organized, controlled manner.
- Allowed servers to reboot only when necessary, with detailed logs to track each step.
- Automated Reporting: Using automation tools, we created a weekly email report that included:
- Clear, color-coded statuses for each server (e.g., updates pending, updates completed).
- Logs showing exactly what was updated and when.
- A transparent view for the client and our team, eliminating uncertainty.
- Phased Rollouts: Updates were deployed in smaller groups at first, allowing us to test and refine the process before rolling it out across the entire system.
The result was a streamlined patching process that fit seamlessly into their operation—no more unexpected downtime. And no more servers deciding to “live their truth” with rogue reboots.
Better Than Fighting Midweek Reboots: Consolidated Maintenance & Automated Reporting
Here’s how our solution improved their operations:
- Scheduled Updates: All updates were consolidated into a single, planned maintenance window each Sunday.
- Consistent Uptime: The client avoided costly interruptions, keeping production on track and profits secure.
- Simplified Compliance: Automated reporting made it easy to track updates and meet audit requirements.
- Renewed Focus: Their IT team regained trust in the process, freeing them to focus on bigger projects.
This success marked the beginning of an ongoing partnership. With a reliable patching system in place, the client is now working with us to explore additional IT improvements.
Stop Letting Unplanned Downtime Erode Your Revenue
In manufacturing, unplanned downtime doesn’t have to be the cost of doing business. We’ve spent years helping manufacturing clients minimize downtime and maximize profitability through streamlined, efficient, and secure IT management.
Here are just a few ways we support manufacturing companies like yours:
If you have enough tasks for 20 engineers but are stuck doing it with two or three, our Co-Managed IT solutions are the perfect fit. We can help transform your small team into one with the capabilities of 20—at less than the cost of a single full-time employee.
We’d love to show you how we can help fill your gaps, streamline your systems, and keep your operations secure, efficient, and profitable.
