Migrating to IBM Maximo Application Suite 9.1 (MAS 9.1) has become essential for any organization still running Maximo 7.6.1.x, whose standard support ends in September 2025. This upgrade represents far more than a version bump: it shifts you onto a modern, secure, AI-optimized EAM platform built to meet today's regulatory and business demands. Drawing on experience from five complete Maximo migrations, this article delivers a deep, methodical, and hands-on roadmap to maximize your MAS 9.1 rollout success.
Why Migrate Now? Benefits and Challenges
Strategic Context
· End of support for Maximo 7.6.1.x means no more security patches, loss of ISO compliance, heightened risk of critical failures, and rising maintenance costs.
· MAS 9.1 emerges as the new baseline with cloud-native architecture, built-in AI, performance enhancements, and continuous modernization.
· Licensing shifts to AppPoints, with dual licensing available until 2027 and full support retirement thereafter.
Expected Benefits
· A modular, scalable platform on OpenShift.
· Advanced capabilities: IoT integration, predictive analytics, mobile maintenance, and generative AI.
· IBM-backed security, compliance, and support.
· Strong ROI through operational efficiency and reduced risk.
Major Challenges
· Significant technical leap (Java 17, removal of Nashorn, API changes).
· Migrating customizations, interfaces, and critical data history.
· Managing organizational change for business users and IT staff.
Lessons Learned: Five Migration Projects
1. Diagnostic and Inventory
Conduct a thorough audit of each client's existing Maximo environment: versions, customizations, integrations (ERP, IoT, analytics), data volumes, and technical dependencies (APIs, scripts, BIRT reports). This baseline identifies risks and sets migration priorities.
2. MAS 9.1 Sandbox with Java 17: Setup, Testing, and Training
Stand up an isolated MAS 9.1 sandbox on OpenShift 4.16. Gradually import critical components and run exhaustive tests for Java 17 compatibility, custom packages, end-to-end business processes, and performance under load. Early detection of errors (missing classes, API mismatches, regressions) delivers peace of mind before going live.
3. Data and Customization Migration
Package all custom artifacts (scripts, web.xml, Java classes, integrations) into the MAS 9.1 archive format. Follow IBM's migration guidelines to preserve data models, workflows, configurations, and extensions (Maximo Everyplace, mobile apps, etc.) without loss.
4. Production Cutover Planning: Phased Approach
Schedule the cutover during a low-activity window, with a validated rollback plan, proactive communication to stakeholders, and on-call IT support. Execute in phases-core modules first, then add-ons, then external interfaces-to limit risk and focus on critical functionality.
5. Post-Migration Run: Monitoring, Support, and Knowledge Capture
Implement an intensive post-go-live monitoring phase: track logs, KPIs (CPU, memory, transaction volumes), validate business use cases with key users, and document lessons learned to refine future upgrades.
Migration process
Practical Tutorial: Key Steps to Migrate to MAS 9.1
1. Preparation and Inventory
o Map business processes, custom objects, data flows, and licenses.
o Assess feature criticality to determine migration order.
2. Build a MAS 9.1 Sandbox
o Install OpenShift 4.16 and core MAS components.
o Configure foundational settings and import representative test data.
3. Validate Java 17 and New Frameworks
o Execute all scripts, reports, APIs, and ERP integrations.
o Proactively fix broken dependencies and adjust code.
4. Migrate Data and Deploy Custom Archive
o Follow IBM's archive creation guide.
o Automate migration of history, workflows, assets, and escalations.
5. Conduct Thorough Functional and Technical Testing
o Perform end-to-end reviews of all critical processes.
o Run controlled performance tests to anticipate production peaks.
6. Execute Cutover and Communication Plan
o Confirm the optimal migration window.
o Provide user guides, FAQs, and on-site support.
7. Monitor and Capture Feedback
o Intensify monitoring for the first week.
o Record challenges and successes to establish an improvement backlog.
Illustration of the impacts for administrators, users, and developers
Trend Analysis: MAS 9.1-Evolution or Revolution?
MAS 9.1 is not merely a new release; it redefines modern EAM with a hybrid-cloud focus, big-data scalability, native scale-out, and embedded AI. The Java 17 migration and OpenShift integration pave the way for continuous security enhancements, elasticity, and forward-looking innovation-critical to handling IoT, resilience, and the convergence of AI/OT/IT over the next decade. Early adopters report reduced IT overhead, faster deployment cycles, stronger predictive maintenance via AI, heightened security for ISO and OT/IT audits, and plug-and-play flexibility with mobile and cloud native services.
Conclusion and Expert Recommendations
Migrating to MAS 9.1 is more than a technical mandate; it's a strategic chance to align asset management with future standards. Success hinges on rigorous planning, a robust pilot phase, attentive change management, and systematic knowledge capture.
Key Recommendations:
· Start early-don't wait until late 2025.
· Document each step in detail.
· Involve all stakeholders from day one.
· Leverage community resources (Maximo user groups, TechXchange).
· Measure and communicate business ROI after go-live.
By mastering the MAS 9.1 migration process, your organization will secure compliance, optimize performance, and cement its digital leadership for years to come.
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Mahdi Salah
Senior Consultant IBM Maximo & MAS 9
SINORFI
TUNISIE
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