Zero-downtime migration of legacy on-premise infrastructure to AWS with Kubernetes orchestration and IaC.

ManufactureCo ran 40+ applications on aging on-premise servers with manual deployment processes. Infrastructure costs were escalating, scaling during peak production periods was impossible, and the operations team spent 70% of their time on maintenance rather than innovation. The company needed to modernize without any disruption to their 24/7 manufacturing operations.

We designed a multi-AZ AWS architecture with EKS for Kubernetes orchestration, implementing a blue-green deployment strategy for zero-downtime migration. All infrastructure was codified using Terraform modules, with state managed in S3 with DynamoDB locking. We containerized each application with Docker, created Helm charts for consistent deployments, and built CI/CD pipelines in GitHub Actions with automated testing, security scanning, and progressive rollouts. Datadog was integrated for comprehensive observability with custom dashboards and alerting.