Enterprise Network Upgrade for Manufacturing: Migration from Fortinet to Ubiquiti

Introduction

Magnetic Component Engineering, a mid-sized manufacturing firm, grappled with an outdated IT system that was costly and tough to manage. YesTechie upgraded their infrastructure to advanced, scalable technology, slashing licensing fees and streamlining operations.

Client Overview

Magnetic Component Engineering (MCE), a mid-sized firm in Torrance, California, provides permanent magnets and magnetic assemblies to the aerospace, defense, medical, semiconductor, and industrial manufacturing sectors since 1973. MCE is addressing challenges in scaling operations, managing a complex supply chain, integrating systems with customers and suppliers, and meeting strict industry regulations. These challenges highlight the need for a robust IT infrastructure to support advanced manufacturing, quality control, and customer service.

The Technical Challenge

The client required a unified, easily manageable network system with a user-friendly interface, featuring a VPN server with seamless integration into Microsoft 365 Entra ID and a scalable site-to-site VPN to connect multiple locations. The use of mixed hardware (Ubiquiti Wi-Fi access points and controller paired with a Fortinet gateway/firewall) complicated network maintenance. Additionally, the project involved modernizing the MDF to improve organization and efficiency, as well as enabling integration with new AI security cameras to enhance surveillance capabilities.

Solution Implemented by YesTechie

Fortinet to Ubiquiti Migration:
High Availability Setup (Shadow Mode) for Ubiquiti Enterprise Fortress Gateway

The High Availability Setup (Shadow Mode) for Ubiquiti EFG is a feature designed to ensure uninterrupted network operation using two EFG devices: a primary unit and a secondary (shadow) unit. Under normal conditions, the primary EFG manages network traffic, while the shadow EFG mirrors its settings and state. If the primary unit fails, the shadow unit automatically takes over—often using protocols like VRRP (Virtual Router Redundancy Protocol)—maintaining network continuity with minimal disruption.

Benefits

• Reliability: Reduces downtime by providing a dependable failover mechanism.
• Seamless Transition: Switches to the shadow unit quickly and automatically, typically unnoticed by users.
• Simplified Management: Syncs configuration changes from the primary to the shadow, easing administrative tasks.
• Cost-Effective: Delivers enterprise-grade reliability without the need for costly proprietary solutions.

This setup is ideal for environments where network uptime is critical, offering a robust and efficient solution for operational continuity.

Site-to-site VPN

Ubiquiti Site Magic is a feature within the UniFi ecosystem that simplifies the setup of secure Site-to-Site VPN connections between UniFi Gateways. It uses SD-WAN technology to automate the creation of VPN tunnels, supporting both Hub-and-Spoke and Mesh topologies. For a client with locations nationwide, the Mesh option stands out, enabling direct, high-performance connections between all sites.

Technology

• Automated VPN Configuration: Site Magic streamlines the process, eliminating the complexity of manual VPN setups.
• Topology Flexibility: Hub-and-Spoke for centralized control or Mesh for direct site-to-site links.

Benefits for Multi-Location Clients

• Simplified Deployment: Quick setup saves time and reduces technical overhead.
• Scalability: Supports up to 20 sites, perfect for nationwide operations.
• Performance & Resilience: Mesh topology offers low-latency connections and failover paths if a link drops.
• Seamless Resource Sharing: Enables efficient access to applications and data across locations.
• Dynamic Adaptation: Automatically adjusts to changing WAN IP addresses, ensuring consistent connectivity.

VPN Server with UniFi Identity

Setting up a VPN server for employees can often be challenging, especially with an existing identity provider for authentication (in our case, Microsoft 365 - Entra ID). UniFi Identity Enterprise offers a multi-platform solution (Windows, MacOS, Linux, iOS, Android) with easy integration capabilities. It supports Google SSO, Microsoft 365, Active Directory, and LDAP.

Firewall

UniFi Network allows you to configure essential firewall security protocols, such as content filtering, intrusion prevention, VLAN isolation, etc. It is worth noting that on the Enterprise Fortress Gateway (EFG), enabling these features does not impact network performance. All advanced features are part of UniFi and do not require paid subscriptions.

MDF Upgrade (Cable Management and Rack Installation)

For managing large networks with a vast number of wired connections, maintaining a clean and organized network rack is crucial. Ubiquiti's cable management accessories make this easy, enabling seamless organization while supporting maximum bandwidth for connected equipment. For the company's IT manager, working with such a well-organized rack is both convenient and straightforward.

Implementation

For an operating enterprise, network downtime is critical. We conducted all work during non-working days to minimize disruption. The migration of all existing Fortinet settings had to be completed immediately and in full, as certain devices on the network rely on DNS servers accessed via a site-to-site VPN connection to the data center. Prior to the start of the new workweek, we verified that all network components were fully operational, all VLANs were correctly configured, and all wireless networks were functioning in normal mode. Ubiquiti’s technologies enabled us to successfully complete all assigned tasks within the designated timeframe and without any unexpected issues.

• Network Core Upgrade: The old Fortinet FortiGate 100F was replaced with two Ubiquiti Enterprise Fortress Gateway units operating in high-availability mode to enhance reliability.
• Switch Infrastructure: 17 UniFi switches were configured and tested to manage network traffic efficiently and ensure optimal performance.
• Wireless Network: The 15 existing UniFi WiFi access points were reconfigured and tested to integrate seamlessly with the new network, ensuring consistent wireless performance.
• Cabling: 300 network connections were re-terminated and tested to maintain the integrity and reliability of the physical infrastructure.
• Rack and Cable Management Upgrade: The old racks were upgraded with new ones, and all cables were reordered and rerouted to 12 new 24-port patch panels, significantly improving cable management and organization.
• Security Enhancement: A UniFi NVR Pro and UNAS were installed to manage security cameras, improving surveillance capabilities.

Results and Business Impact

Measurable Outcomes

• Elimination of recurring subscription fees: By adopting Ubiquiti, MCE removed the ongoing licensing costs tied to Fortinet, leading to meaningful savings in operational expenses.
• Enhanced network uptime: The Ubiquiti system improved reliability, minimizing disruptions and maintaining steady performance for essential manufacturing processes.
• Quicker response times: The new setup streamlined system management and troubleshooting, enabling the IT team to address issues faster and keep operations running smoothly.

Qualitative Benefits

• Simplified system management: Ubiquiti’s platform made network administration more straightforward, easing the burden on IT staff and freeing them up for higher-priority tasks.
• Better scalability: The infrastructure now supports growth across multiple locations, preparing MCE for future expansion without requiring major system changes.
• Greater reliability and redundancy: The upgraded system is more durable and less prone to failures, which is vital for manufacturing environments where downtime can stop production entirely.

Business-Level Impacts

• Boosted production capacity: With fewer system outages, MCE can sustain higher levels of output, directly strengthening its manufacturing capabilities.
• Increased employee productivity: A dependable network allows staff to complete critical tasks without delays, improving overall workplace efficiency.
• Lowered risk of downtime: The resilient and redundant Ubiquiti setup reduces the chances of costly operational interruptions, protecting MCE’s multi-site manufacturing operations.

Conclusion

The enterprise network modernization for Magnetic Component Engineering transformed their outdated and costly IT infrastructure into a scalable, reliable, and cost-efficient system powered by Ubiquiti. By eliminating Fortinet subscription fees, enhancing network uptime, and enabling seamless management across multiple locations, YesTechie delivered a future-proof solution that boosted production capacity and employee productivity. This successful migration ensured MCE’s manufacturing operations are now supported by a robust, unified network, ready to meet current demands and future growth with confidence.