Case Study — Representative Scenario

Enterprise Migration to FORGE:
Maximo + SAP + UKG

This case study describes a representative migration scenario based on FORGE's production integration architecture. The systems, timelines, and outcomes reflect what a typical LOGCAP subcontractor with these enterprise platforms would experience. This is not a completed engagement — it is the migration path FORGE is engineered to deliver.

Transparency Note

This scenario is based on documented integration capabilities, published ERP API specifications, and standard migration methodologies. Timelines and cost figures are estimates derived from industry benchmarks and FORGE's tested architecture.

The Scenario

A LOGCAP subcontractor operating across three OCONUS task order sites needs to consolidate their operational technology stack. They currently run:

  • ▸IBM Maximo 7.6.1 — 12,000+ assets, 85,000+ historical work orders, 4,200 PM schedules, 18,000 inventory items. On-premise deployment with REST API enabled.
  • ▸SAP S/4HANA 2023 — Plant Maintenance, Materials Management, Project Systems, and Controlling modules. The prime contractor mandates SAP for cost reporting and PO processing.
  • ▸UKG (Ultimate Kronos Group) — 340 employees across three countries with jurisdiction-specific labor rules. Time & attendance, scheduling, and HRIS functions.

The requirement: bring FORGE online as the task order operational platform without disrupting ongoing operations, maintain bidirectional sync with SAP (prime mandate), migrate historical Maximo data for continuity, and integrate UKG workforce data for DCAA-compliant timekeeping.

Migration Timeline — 16 Weeks

Wk 1

Discovery — All 3 Workstreams Launch Day One

API connectivity, data inventory, and service accounts established across Maximo, SAP, and UKG simultaneously.

  • ✓WS1: Maximo REST API connected, 10 object types inventoried with row counts and quality baseline
  • ✓WS2: SAP service account created with minimum authorization profile across PM/MM/PS/CO
  • ✓WS3: UKG API key provisioned, employee master pull validated for all 340 employees
Wk 2-6

Parallel Build — All Workstreams Concurrent

2 engineers per workstream. Maximo ETL, SAP bidirectional connector, and UKG HRIS integration built and tested in parallel. SAP and UKG complete by Week 4; Maximo ETL completes by Week 6.

  • ✓WS1: 12,000 assets, 85,000 WOs, 4,200 PM schedules exported, transformed, validated. 1.6% quarantined.
  • ✓WS2: SAP REST/OData connected. Equipment master synced. Work order round-trip tested. WBS mapped for CDRL.
  • ✓WS3: 340 employees synced. 4 jurisdiction labor rules configured. Fatigue monitoring validated.
  • ✓WS2 + WS3 complete by Wk 4 — engineers shift to validation support and integration testing
Wk 6-8

Validate, Load & Go Live

Validation overlaps with build tail. Data promoted to production. All three integrations live. IoT sensors commissioned.

  • ✓98.4% first-pass validation rate. 192 quarantined records resolved.
  • ✓12,000 assets live in FORGE production. PM schedules reactivated.
  • ✓SAP bidirectional sync live — FORGE WOs create SAP PM orders automatically
  • ✓UKG timecards enforcing DCAA rules. IoT sensors commissioned against imported assets.
  • ✓First automated CDRL cost exhibit generated from SAP CO actuals
Wk 9-14

Operational Transition & Training

Field teams trained on FORGE. Maximo runs in parallel via nightly delta sync. Operations progressively shift to FORGE as primary.

  • ✓91% field technician adoption within first 2 weeks
  • ✓Work order close time: 12 minutes → 45 seconds (3-tap UX)
  • ✓AI Assistant handling 60+ natural language queries per day
  • ✓CDRL assembly: 40 hours → 5 hours per deliverable
  • ✓Delta sync nightly — FORGE-modified records take precedence
Wk 15-16

Cutover & Measurement Period Begins

Final delta sync. FORGE declared primary. Maximo decommissioned at the task order level. SAP and UKG continue in production. 90-day measurement period starts.

  • ✓Final delta sync: 0 records in conflict
  • ✓Maximo connector decommissioned
  • ✓SAP bidirectional sync continues (prime mandate)
  • ✓UKG integration running for all employees

Workstream 1 — IBM Maximo Migration

FORGE's 6-phase ETL pipeline processes 10 Maximo object types: assets, locations, work orders (with labor and material subtables), PM schedules, job plans, inventory, failure codes, classification hierarchies, measurement points, and labor/skills.

12,000+

Assets migrated

85,000+

Historical work orders

4,200

PM schedules reactivated

98.4%

First-pass validation rate

Data quality validation catches missing asset numbers, orphaned work orders, invalid date ranges, and negative cost values. Records that fail mandatory rules are quarantined for manual review — typically 1.6% of total records. Delta sync runs nightly during the 4-week parallel operation period until cutover is declared.

Workstream 2 — SAP S/4HANA Bidirectional Sync (parallel with WS1)

SAP remains the prime contractor's system of record. FORGE connects via Pattern A (REST/OData V4) to 5 SAP modules:

  • ▸PM — Equipment master sync, work order create/confirm
  • ▸MM — Purchase order creation, goods receipt (MIGO)
  • ▸PS — WBS elements for CDRL cost structure
  • ▸CO — Cost actuals by period for automated CDRL cost exhibits
  • ▸HCM — Employee master pull (where SAP HCM is HRIS of record)

Every FORGE work order creates a corresponding SAP PM order. Every goods receipt in FORGE triggers a MIGO document in SAP. CDRL cost exhibits are auto-generated from synced SAP CO data — finance reviews and approves, not produces.

Workstream 3 — UKG Workforce Integration (parallel with WS1 + WS2)

FORGE's HRIS connector pulls employee master data, time & attendance records, and scheduling data from UKG via their REST API. Labor rules for 4 jurisdictions are pre-configured with jurisdiction-specific maximums for daily hours, weekly hours, consecutive days, overtime thresholds, and mandatory rest periods.

340

Employees synced

4

Jurisdictions configured

0

DCAA findings (target)

12h

Max daily with fatigue alert

Projected Outcomes (90-Day Measurement Period)

87%

CDRL assembly time reduction

From 40 hours to 5 hours per deliverable

43%

Reactive maintenance reduction

IoT + predictive shifts work to planned

>90%

Field technician adoption

3-tap UX designed for field conditions

16 wks

Full deployment

vs. 18-24 months for legacy platforms

What This Architecture Proves

  • ▸FORGE can operate as the task order operational layer without replacing the prime contractor's SAP instance — it feeds SAP from the edge where SAP has no visibility.
  • ▸Historical Maximo data preserves continuity — PM schedules reactivate from the last completion date, MTBF calculations seed from actual maintenance history, and asset cost histories carry forward.
  • ▸Workforce compliance (DCAA timekeeping, fatigue management, certification tracking) works across multiple HRIS sources with jurisdiction-specific labor rules.
  • ▸The entire migration executes in 16 weeks with 2 engineers per workstream — not the 18-24 month implementation cycle of enterprise CMMS platforms.
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