Local database autonomy enabling 24/7 production during cloud ERP outages.
Industry: Food Manufacturing
Quick Facts
| Attribute | Value |
|---|---|
| ERP | Microsoft D365 (Cloud) |
| MES | GE Plant Applications |
| Historian | GE Proficy Historian |
| Front End | FrameworX dashboards |
| PLCs | Rockwell Automation |
| Scope | 2 plants, 100+ clients, redundant servers per plant |
| Autonomy | 2-3 days without ERP connectivity |
The Challenge
Challenge: After moving ERP to Microsoft D365 in the cloud, protect highly automated 24/7 production from cloud ERP unavailability (scheduled maintenance, system updates, or unplanned outages).
Specific pain points:
- Cloud ERP outages could stop 24/7 production
- Even 2-3 day disruption would result in millions of dollars in lost revenue
- Customer orders would be disrupted during any ERP downtime
- No local autonomy — plant floor fully dependent on cloud connectivity
Impact: Without survivability layer, any cloud ERP outage directly halts production and causes significant revenue loss.
The Solution
Architecture
| Tier | Component | Capabilities |
|---|---|---|
| Cloud | Microsoft D365 ERP | Enterprise orders, inventory, BOMs |
| Survivability | Local Database + Web Services | 2-3 days autonomous operation |
| MES | GE Plant Applications | Production execution |
| Historian | GE Proficy Historian | Time-series data |
| Front End | FrameworX Dashboards | Operator interface, scheduling, adjustments |
| Control | Rockwell PLCs | Production lines |
Data Flow
Microsoft D365 ERP (Cloud) ↔ Survivability Database (Local) ↔ MES (GE Plant Applications)
↓
FrameworX Dashboards
↓
Rockwell PLCs & Production Lines
Survivability Capabilities
| Function | Description |
|---|---|
| Production Orders | Local management during ERP outage |
| BOMs/Formulas | Cached locally for production continuity |
| Inventory | Lot-level tracking maintained offline |
| Genealogy | Full traceability preserved during disconnection |
| Synchronization | Automatic sync when ERP connectivity restored |
Scale
- 2 plants
- 100+ clients
- Redundant servers per plant
Key Enablers
FrameworX capabilities that made this solution possible:
| Capability | Application |
|---|---|
| Local Database Survivability | 2-3 days of autonomous operation without ERP |
| Web Services Synchronization | ERP ↔ MES ↔ Plant floor data exchange |
| Flexible GUI | Scheduling, order execution, and adjustments |
| Genealogy Preservation | Full lot-level traceability maintained during disconnection |
The Results
- Uninterrupted Production — 24/7 operations continue during ERP outages
- Revenue Protection — Millions in potential daily losses avoided
- Extended D365 Capability — Enabled true shop-floor continuity for cloud ERP
- Compliance-Ready Traceability — Full genealogy across orders and materials maintained
This case demonstrates ERP survivability architecture enabling production continuity during cloud system outages.
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