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We migrate manufacturing workloads to AWS with the operational discipline that factory environments require: phased migrations that avoid production disruption, on-prem historian data consolidation, and SCADA-to-cloud integration patterns that preserve OT network security boundaries.
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Migrate manufacturing IT systems, historian data, and MES applications to AWS using the AWS Migration Acceleration Program (MAP) methodology — while maintaining production continuity and OT/IT separation.
AWS Migration Acceleration Program (MAP) provides funding, tooling, and methodology for migrations to AWS. For manufacturers, MAP typically funds the assessment phase (application discovery, TCO analysis), the migration of IT systems (ERP, MES, historian), and AWS Well-Architected reviews. OT/IT integration work is typically in scope as new development, not migration.
Yes. Common approaches: (1) Deploy PI Server on EC2 and use AWS Database Migration Service to move historical data, or (2) migrate to a cloud-native time-series store — Amazon Timestream or IoT SiteWise — using a custom ETL that reads PI archive data and writes to the new store. The second approach avoids ongoing PI licensing costs.
Deploy AWS IoT Greengrass gateways during the migration period to act as the data collection layer. Greengrass connects to existing SCADA/historian systems via OPC-UA within the OT network, forwards data to AWS via encrypted MQTT, and maintains the security boundary. The SCADA system never connects directly to AWS or the internet.
Phase 1 (Assessment): 4-6 weeks — application discovery, dependency mapping, TCO analysis. Phase 2 (Foundation): 4-8 weeks — landing zone setup, network connectivity (Direct Connect or Site-to-Site VPN), security baseline. Phase 3 (Migration): 12-24 weeks — workload migrations in waves, parallel run validation. Total: 6-10 months for mid-size manufacturing IT portfolios.
Industrial historians (OSIsoft PI, Wonderware, eDNA) and MES systems contain decades of production data and are tightly integrated with plant floor systems — migrating them without disrupting production requires specialized cutover planning.
Many manufacturing IT systems have undocumented dependencies on OT network resources — historian servers that poll PLCs directly, MES systems that read from SCADA databases. These dependencies must be mapped before migration.
Factory environments cannot tolerate extended downtime for migration cutover. Migrations must be designed for zero-downtime or planned maintenance window cutover — not the weekend migrations typical of IT applications.
ITAR, CMMC, ISO 9001, and other manufacturing compliance frameworks impose requirements on data handling and system access that must be maintained throughout the migration process.
AWS Migration Acceleration Program (MAP) assessment, mobilization, and migration phases applied to manufacturing workloads — including historian consolidation to S3-based data lakes, MES application re-platforming, and OT data integration.
Historian data migration with parallel run validation — new AWS IoT SiteWise or Amazon Timestream receiving live telemetry alongside on-prem historian for 4-6 weeks before cutover, ensuring data parity before decommissioning on-prem systems.
AWS IoT Greengrass gateways as the migration bridge — collecting data from existing SCADA systems via OPC-UA and forwarding to AWS cloud while maintaining OT network isolation throughout and after migration.
Talk to our AWS experts about aws cloud migration for manufacturing workloads.
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