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Case Studies: Real Results for Real Manufacturers

How We Help Manufacturers Solve Technology Challenges

Every manufacturer we work with has a different starting point, but the challenges share common themes: unreliable systems, security concerns, aging infrastructure, and IT that hinders operations rather than supporting them. These case studies illustrate how Neuron transforms technology environments for manufacturers nationwide.

Case Study 1: From Weekly Outages to 99.99% Uptime

Industrial factory floor with machinery and safety markings

Aerospace Parts Manufacturer | Chatsworth, CA | 85 Employees

The Challenge

This precision machining company serving the aerospace and defense industry was experiencing weekly network outages lasting anywhere from 30 minutes to half a day. Their single IT person had left the company, and they were relying on a break-fix provider who took hours to respond and billed by the hour. Every outage meant CNC machines sitting idle, ERP inaccessible, and shipping deadlines missed.

Their aging server infrastructure was running on hardware well past its warranty period. Backups existed but had never been tested. The network was a flat, unsegmented mess that had grown organically over a decade. They had recently received a notification from a prime contractor that NIST 800-171 compliance would be required to maintain their contracts.

Our Solution

Neuron conducted a comprehensive infrastructure assessment and developed a phased remediation plan. In the first 90 days, we:

  • Deployed our remote monitoring and management platform across all servers, workstations, and network devices
  • Replaced end-of-life servers with redundant, properly configured infrastructure
  • Redesigned the network architecture with proper segmentation, redundant switches, and managed firewalls
  • Implemented automated, tested cloud backups with immutable storage
  • Began the NIST 800-171 compliance journey with a gap assessment and System Security Plan

The Results

  • Network uptime improved from approximately 95% to 99.99% in the first year
  • Zero unplanned outages lasting more than 15 minutes
  • Achieved NIST 800-171 compliance within eight months, securing their defense contracts
  • IT support response time dropped from hours to under 15 minutes
  • Annual IT costs decreased by 22% compared to the combined cost of their previous IT employee and break-fix provider

Case Study 2: Ransomware Stopped Before It Started

Workers on a modern production line

Plastics Manufacturer | Ventura County | 120 Employees

The Challenge

This injection molding company had experienced a ransomware attack that encrypted their file server and ERP database. Recovery from their most recent backup took three days, during which production operated on paper and manual processes. The attack cost an estimated $180,000 in lost production, emergency IT services, and recovery efforts.

After the attack, they engaged Neuron to prevent it from happening again. Their existing security consisted of consumer-grade antivirus software on some workstations (not all), no email filtering beyond the defaults, and no network segmentation between office computers and production floor systems.

Our Solution

We implemented a layered cybersecurity program designed to prevent, detect, and respond to threats:

  • Deployed enterprise endpoint detection and response (EDR) on every device, replacing the patchwork of antivirus installations
  • Implemented advanced email security with sandboxing, phishing protection, and DMARC/DKIM/SPF
  • Enrolled the entire company in security awareness training with monthly simulated phishing campaigns
  • Segmented the network to isolate IT systems from OT (injection molding machine controllers) and implemented firewall rules controlling traffic between segments
  • Deployed immutable cloud backups that cannot be encrypted by ransomware
  • Connected their environment to our 24/7 SOC for continuous monitoring
  • Developed and tested an incident response plan with the leadership team

The Results

  • Zero successful ransomware attacks in the three years since engagement
  • Our SOC detected and blocked two ransomware attempts in the first 18 months, both originating from phishing emails that bypassed the first layer of email security but were caught by EDR
  • Phishing simulation click rates dropped from 32% to under 4% within the first year of training
  • Network segmentation prevented a compromised office workstation from reaching any production equipment during one of the blocked attacks
  • The company now carries cyber insurance at a lower premium due to their improved security posture

Case Study 3: Cloud Migration Without Missing a Shipment

Assembly line and conveyor system in a modern manufacturing facility

Food Processing Manufacturer | Oxnard, CA | 200 Employees

The Challenge

This food manufacturer operated two production facilities and an administrative office, all connected by aging VPN tunnels over unreliable internet connections. Their on-premises ERP server was seven years old and running on a single physical machine with no redundancy. File shares were scattered across multiple servers at different locations with inconsistent backup coverage.

A planned facility expansion would add a third production site, and the existing infrastructure could not scale to support it. The IT manager was spending most of their time firefighting infrastructure issues rather than supporting the business.

Our Solution

We designed and executed a phased cloud migration to Microsoft Azure, combined with a Microsoft 365 deployment:

  • Phase 1: Migrated email from on-premises Exchange to Exchange Online and deployed Microsoft Teams for cross-site communication
  • Phase 2: Migrated file shares to SharePoint Online with local caching at each facility for fast access, replacing the fragmented file server environment
  • Phase 3: Migrated the ERP database to Azure SQL with high availability and geo-redundant disaster recovery
  • Phase 4: Replaced the aging VPN infrastructure with SD-WAN for multi-site connectivity, improving bandwidth and reducing telecom costs
  • Phase 5: Deployed the technology infrastructure for the new facility, connecting it to the cloud environment from day one

The entire migration was executed over six months without a single unplanned production disruption.

The Results

  • ERP availability improved from approximately 97% to 99.99% with Azure high availability
  • File access speed improved at remote locations thanks to local caching and SD-WAN
  • The new facility was fully operational from an IT perspective on opening day
  • Disaster recovery capability went from "untested three-day recovery" to a verified four-hour RTO
  • The IT manager now spends 80% of their time on strategic initiatives instead of infrastructure maintenance
  • Monthly IT infrastructure costs became predictable and decreased by 15% compared to maintaining on-premises hardware

Your IT Transformation Starts Here

These results are not exceptional. They are the standard outcome when operational companies work with an IT provider that specializes in their industry and takes a proactive approach to technology management.

Whether you are dealing with unreliable infrastructure, cybersecurity concerns, aging systems, or growth that has outpaced your IT capabilities, Neuron has the experience and methodology to stabilize your technology environment. We serve manufacturers, HVAC companies, plumbing contractors, electrical contractors, and construction companies nationwide.

Read about our structured approach to learn how we deliver these results consistently.

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