Case Study

Challenges
Project Journey
Results

Reduced Processing Time from 32 to 10 hours

Monthly Savings Reduction of infrastructure costs

Reduced Maintenance Effort Consolidated 3 Kubernetes Pods into 1

LEAN-CODERS optimized the critical Core Processing Engine of an internationally leading manufacturer of gas engines to monitor thousands of power generators worldwide. Through architecture modernization and code consolidation we were able to reduce the processing time from 32 to under 10 hours successfully.

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 demands.
Legacy Architecture

Outdated Visual Basic code with complex network handovers between isolated systems, hard to maintain and prone to errors.
Lack of Transparency

Millions of machine messages daily, but no efficient method to validate state changes and algorithms.
Infrastructure Overhead

Three separate Kubernetes Pods for processing, high ongoing costs.

Project Journey

Analysis & Simulation

We built a comprehensive simulation environment using JavaScript (Node.js) and complete unit tests. Millions of messages could be sent through both old and new systems to precisely identify discrepancies.

This investment paid off – we discovered that the originally desired Python solution would have been even slower than the legacy system.

Gelbe Ente mit Sonnenbrille hält zwei Spielzeugpistolen, darüber der Schriftzug „Pew Pew“.

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 handovers between systems by consolidating everything into a single, optimized Java codebase.

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.

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.