Carhartt Achieves Zero Downtime with SUSE-Powered SAP S/4HANA Migration

Workwear manufacturer Carhartt has completed the first phase of its digital transformation, migrating from legacy AS400 systems to SAP S/4HANA running on SUSE Linux Enterprise Server for SAP Applications in Microsoft Azure. The move has eliminated monthly outages that previously cost the company up to $1 million per hour in lost revenue while positioning the 135-year-old company for omnichannel growth.

The Dearborn-based company, known for its durable workwear, launched its cloud-first strategy to support its expansion from traditional wholesale operations into direct-to-consumer and direct-to-business channels.

Tim Masey, Vice President of IT Infrastructure & Security at Carhartt, highlighted the limitations of their current infrastructure as a key reason for change. “When we’re down for an hour in any of our distribution and fulfillment areas, we could be losing a million dollars. So, the cost of availability for us was really important in terms of driving our transformation.”

The company’s internal data center faced significant operational challenges, as systems were installed in cramped spaces that were difficult to maintain and would go down about once a month. In addition to reliability concerns, the AS400 systems provided limited scalability compared to modern cloud-based options, which limited Carhartt’s ability to adopt technologies like Kubernetes-based containerization.

Strategic Technology Selection and Implementation

Following SAP’s recommendation, Carhartt chose SUSE Linux Enterprise Server for SAP Applications as their operating system, supported by SUSE Multi-Linux Manager for deploying security templates and managing patches. The decision was driven by SUSE’s strong partnership with SAP and Microsoft.

The migration strategy focused on security integration from the beginning, with Masey’s team working across multiple vendors to ensure systems were launched with proper security measures. ” From a security perspective, one of the first things we looked for was the ability to easily manage, secure and harden the operating system to make sure it can work within our security model,” Masey noted.

The implementation’s success even surprised internal skeptics. The AS400 support team, initially resistant to the cloud migration, eventually recognized that the new environment offered capabilities that their legacy infrastructure couldn’t match. They lauded the quick system deployment, resource management, and disaster recovery features compared to their previous on-premises setup.

Since completing the retail business migration, Carhartt has maintained 24/7 system availability with no major outages. This success has enabled the IT team to shift their focus to preparing for phase two: migrating their core wholesale business operations. The company is currently conducting extensive testing of development environments, role management systems, and security procedures.

What This Means for SAPinsiders

Zero downtime migrations lower operational risk and prevent revenue loss. For IT leaders, Carhartt’s success story highlights the real financial advantages of reducing outages during critical ERP transitions. Companies in industries where downtime directly causes lost sales or supply chain issues can learn valuable lessons here. SAP executives should focus on solutions with proven records in availability and recovery, especially when essential business functions rely on continuous operations.

Cloud-first strategies boost scalability and business agility. Carhartt’s transition from legacy AS400 systems to SAP S/4HANA in Azure highlights how cloud-based infrastructures support omnichannel growth. For SAP professionals, this highlights the importance of aligning ERP migration with broader digital transformation objectives. By selecting flexible platforms that integrate with Kubernetes and containerization, organizations can accelerate innovation and respond more quickly to market changes.

Vendor alignment facilitates smoother implementations and long-term support. Carhartt’s choice to adopt SUSE Linux Enterprise Server for SAP Applications, supported by SAP and Microsoft partnerships, highlights the importance of partnering with vendors that have strong ecosystem relationships. For executives assessing technology partners, focus should be on vendor collaboration, roadmap alignment, and proven integration support. This approach helps ensure ERP migrations succeed initially and stay stable and secure over time.