Re-architecting Production Resilience for a Leading Tyre Manufacturer with Airtel Cloud

The client was a leading Indian multinational tyre manufacturing enterprise. With an annual production exceeding 48 million tyres and a daily manufacturing capacity of over 800 tonnes, the company produces a comprehensive range of tyres for passenger cars, commercial vehicles, agricultural machinery, and two-wheelers across multiple state-of-the-art manufacturing plants in India. 

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Problem Statement 

The manufacturer was facing significant risks to their operational continuity due to infrastructure limitations: 

• Single point of failure: Leading to a risk of production continuity due to a single Data Center (DC) and operations running on isolated OT networks with MIS (Windows + SQL) and MES systems. 

• 0 real-time replication: Stemming from a lack of network redundancy and the absence of an automated failover mechanism. 

• Legacy & non-replicable workflows: Critical operations were running on physical servers, leading to complex recovery processes and severe downtime exposure. 

Airtel’s Solution 

We designed and deployed a comprehensive disaster recovery and connectivity framework: 

• Eliminate single point of failure: Implemented a Hybrid DR architecture featuring a geographically separate DR site (Airtel Manesar DC) and an independent infrastructure backbone. 

• Real-time replication & automated failover: Enabled continuous Virtual Machine (VM) and database replication with fully orchestrated failover/failback capabilities. 

• End-to-End (e2e) connectivity offering: Leveraged private 5G for seamless data transfer, providing an additional layer of network resilience. 

• Fully managed DR governance: Delivered comprehensive SLA-backed managed services, including 24×7 monitoring, bi-annual DR drills, and strict compliance reporting. 

The Impact 

• Guaranteed Business Continuity: Eliminated the single point of failure, ensuring that manufacturing operations are no longer dependent on a single facility. 

• Minimized Downtime Exposure: Replaced complex legacy recovery processes with automated failovers, drastically reducing recovery time objectives (RTO). 

• Enhanced Network Resilience: Secure, uninterrupted data transfer between the primary site and the DR site via a dedicated private 5G network. 

Conclusion  

By partnering with Airtel, the tyre manufacturer successfully modernized its legacy infrastructure and mitigated severe production risks. The transition to a Hybrid DR architecture equipped with real-time replication and private 5G connectivity bridged the gap between isolated OT networks and modern resilience standards. Ultimately, this strategic upgrade established a highly secure, fully managed foundation to ensure uninterrupted manufacturing operations.