Reduced processing time from 32 to 10 hours
~70%
Case Study
Industry Energy sector
Project Duration 6 months
Team 1 Full Stack Senior Dev
Visual Basic out. Java in. Up to 70% faster.
Monthly savings Reduction of infrastructure costs
€10.000
Reduced maintenance effort Consolidated 3 Kubernetes Pods into 1
3 auf 1
LEAN-CODERS optimized thecritical Core Processing Engineof an internationally leading manufacturer of gas engines to monitor thousands of power generators worldwide. Througharchitecture modernizationandcode consolidationwe were able to reduce the processing time from32 to under 10 hourssuccessfully.
Challenges
The client faced critical challenges in their Reliability Engineering.
- Performance bottleneck
The existing Core Processing Engine for monitoring global power generator fleets took 32 hours for daily data processing – far too slow for modern requirements.
- Legacy architecture
Outdated Visual Basic code with complex network transitions between isolated systems, hard to maintain and prone to errors.
- Lack of transparency
Millions of machine messages daily, but no efficient method for validating state changes and algorithms.
- Infrastructure overhead
Three separate Kubernetes Pods for processing, high ongoing costs.
Project Journey
1
Analysis & Simulation
We built a comprehensive simulation environment with JavaScript (Node.js) and complete unit tests. Millions of messages could be sent through old and new systems to precisely identify differences.
This investment paid off– we discovered that the originally desired Python solution would have been even slower than the legacy system.
2
Architecture redesign
The client was already using Java for parts of the processing. We strategically expanded this existing Java architecture and migrated the critical processing logic from Visual Basic.
The breakthrough:We eliminated the network transitions between the systems by consolidating everything into a single, optimized Java codebase.
3
Implementation & Validation
A LEAN-CODERS Senior Developer worked closely with two experts on the client side. Each optimization was tested against real production data.
The result:fully documented, maintainable Java code with comprehensive unit tests – readable for the entire development team.
4
Deployment & Maintenance
Seamless rollout without downtime.The new Core Processing Engine has been running stably in production since then and is continuously maintained and optimized by us.
Results
Long-term partnership:
The project is one of several successful projects in a multi-year collaboration. Continuous maintenance is ongoing to this day.
We deliver. They stay. Repeat.
Performance
70% faster processing: From 32 hours to under 10 hours per calculation cycle
Consolidated architecture: Reduced three separate Kubernetes Pods to a single one
Costs & Maintainability
~€10,000+ monthly savings through infrastructure optimization (estimated)
Drastic reduction of helpdesk calls thanks to more precise algorithms and better reliability
Fully documented in Confluence with comprehensive unit tests
Technical quality
Modern Java codebase instead of hard-to-maintain Visual Basic legacy code
Foundation for follow-up projects
The new architecture already enabled a second project for other teams in the company
Team-ready
Any Java developer can understand and extend the code
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