The Client

• The client is an automobile giant in North America with 12 plants across the U.S.
• They manufacture various motor products, such as passenger vehicles, engines, transmissions, and components; aircraft and aircraft engines; power equipment; and sports cars.
• The 12 manufacturing plants altogether produce 5.9 million products annually.
• Overall, 27.3 million cars and light trucks have been built in the U.S. by the client.
• Additionally,1.35 million automobiles have been exported from the U.S.

Business Challenges

• High utilization of mainframe CPU slows down online application response time.
• Users observed slowdowns during peak hours, especially during new model production, payroll weekends & month-end reporting periods.
• Users are not able to log into the online application, let alone perform business operations, when there are issues with the batch processes.
• Only 5% of the jobs are completed within 1 hour. Most of the jobs end up waiting too long for CPU time.
• Numerous jobs take 20 hours to complete.
• Batch jobs frequently overrun the batch window missing the SLA 3 times a week and the application is NOT fully functioning at 6:00 AM.
• The performance of the mainframe batch jobs was very poor and only able to meet batch completion SLA 32% of the time.
• High maintenance costs for the legacy mainframe system

Kumaran Solution

• Tool guided migration of COBOL / JCL batch programs to Java Spring Batch, using Kumaran’s proprietary tool NxTran.
• Migration of z/OS DB2 to LUW DB2. Tool guided migration of COBOL DB2 stored procedures to LUW DB2 stored procedures.
• Optimization of online applications to improve performance.
• Spring batch jobs scheduled and monitored using Kumaran’s Quartz Scheduler User Interface.
• Implemented solutions for complex integrations with upstream and downstream applications.
• Performance improvement achieved via Query Optimization.
• Implementation of transactional DB for the online and batch transaction and reporting DB for interfaces, reports, and queries.
• Implemented solution for compatibility of non-COMP3 and COMP3 values.

Solution Benefits

• Estimated 5-year savings of $13.13 million in efficiency hours and maintenance expenses.
• Batch SLA improved from 32% to 99%.
• A future-ready platform that can eventually be evolved into a single, modular, manufacturing system.
• Distributed technology, delivering scalability, reliability, availability, and security of manufacturing systems with industry-leading techniques.
• Improved application performance and user experience. Improved productivity of the end-users.