Astra Daihatsu Motor Ensures Delivery of Information and Avoids Revenue Loss

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Astra Daihatsu Motor Ensures Delivery of Information and Avoids Revenue Loss

Commvault helps Indonesian auto manufacturer achieve high availability of critical production systems and improve customer service

The challenge

  • Deliver timely information to customers by achieving high availability of business-critical production systems
  • Mitigate the risks of losing approximately US$1,000 per minute due to downtime on assembly lines
  • Comply with data protection and regulatory requirements
  • Minimize disruption to manufacturing operations

The benefits

  • Increased production efficiency and ensured timely delivery of information to customers
  • Minimized the risk of losing approximately US$60,000 per hour from system downtime by ensuring high availability of business-critical production systems
  • Reduced recovery time by 80% percent and the backup window by 95% percent
  • Eliminated the need for IT staff to work overtime hours to deal with outages

The solution

  • Commvault Complete™ Backup & Recovery, protecting 140 applications and databases with a single solution
  • Completed implementation in just two weeks with support from Commvault and partner PT Nagitec

Case Study Astra Daihatsu Motor

Industry: Automotive

Headquarters: Jakarta, Indonesia

Ensuring timely delivery of information to customers

Astra Daihatsu Motor is one of the leading Indonesian automotive manufacturers, producing up to 2,000 Daihatsu and Toyota vehicles a day – about 550,000 every year. The company has 12,500 employees and five different sites, including two automotive production facilities, in Jakarta and Karawang, West Java.

Time is money for automotive manufacturers, and every minute counts. To minimize the risk of costly production downtime, IT systems need to be ultra-reliable with fast recovery capabilities.

As Astra Daihatsu Motor’s Head of IT, Akmal Kusumajaya, explains, “Each assembly line produces one vehicle per minute, so every minute the total cost from downtime is approximately US$1,000. It means we could lose almost US$60,000 per hour in the event of an outage.”

reduction in backup window

Kusumajaya had firsthand experience of this when one of the company’s plants suffered a two-hour outage. Back then, the company relied on manual daily backups, so restoring data was a slow, complicated process.

As such, Astra Daihatsu Motor wanted to improve its ability to recover quickly from outages and prevent escalating costs. “An outage would not just impact our revenue, but also cause a delay in scheduled deliveries to customers, and we would need to pay staff overtime to get production back on schedule,” Kusumajaya says.

Eliminating downtime and improving customer satisfaction

Astra Daihatsu Motor’s complex IT environment includes 140 applications, a variety of databases, and 12 terabytes of data, which is forecast to grow by between 5-10% every year. By using Commvault Complete™️ Backup & Recovery, the manufacturer is now confident that the business-critical production systems are automatically backed up without any downtime. Importantly, the IT team only use one console to monitor backups across five manufacturing plants, making it faster to recover data if the company suffers another outage.

“Rather than spending hours every day on manual backups, we now have time to focus on productive tasks. It’s transformed our IT culture,” Kusumajaya says. “We also minimized the delay for customer deliveries, which is critical to ensure customer satisfaction.”

The Commvault solution, which is integrated with an HPE tape library and Fujifilm tape storage system, also enables Astra Daihatsu Motor to reduce the recovery time by 80% – from more than eight hours to just two hours – which has resulted in a 95% shorter backup window.

"With Commvault’s industry-leading backup and recovery solution, we have minimized production downtime and can deliver timely information to customers. Our team is also more productive and no longer needs to work overtime."

Akmal Kusumajaya
Head of IT, Astra Daihatsu Motor

A solution that ensures high availability

After a competitive bidding process and an extensive assessment of the options on the market, Commvault Complete™️ Backup & Recovery was the obvious choice, with rich features fulfilling all of the company’s requirements while still being simple to use.

“Commvault’s position as a market leader gave us further confidence that we were making the right choice,” Kusumajaya says. “We were particularly impressed by its integration capabilities with different applications and intuitive features.”

The solution was deployed in just two weeks across all Astra Daihatsu Motor’s facilities in December 2017. “This was largely due to Commvault’s help in sharing information and responding quickly to support requests,” Kusumajaya says.

The team now has a backup and recovery solution that supports the company’s needs for highly available systems, applications, and data – and they can hit their service-level target.

A secure platform for digital transformation

To meet Astra Daihatsu Motor’s digitalization plans, the solution also needed to be able to support cloud services, while complying with the data protection policies and regulatory requirements of its parent and related companies.

With Commvault Complete™️ Backup & Recovery, Astra Daihatsu Motor can confidently deliver on its digital strategies and meet compliance needs, and next on the agenda is trialing cloud services for end user applications and Commvault’s replication capabilities.

“We have a digitalization roadmap for the next five years, and we know Commvault will support us in our ongoing journey,” comments Kusumajaya.

deduplication rate


Astra Daihatsu Motor in numbers

  • 5 sites including 2 manufacturing facilities in Indonesia
  • 12,500 employees
  • 12 terabytes of data

The backup environment

  • Commvault Complete™️ Backup & Recovery
  • Version 11 HP-UX servers
  • HPE StoreEver MSL2024 Tape Library LTO-7
  • Fujifilm tape backup system

Key assets protected

  • 140 applications
  • SAP ERP and Oracle
  • Approximately 70 database servers, including Oracle, Microsoft SQL, MySQL and firebird
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