The challenge
The company had grown from a small workshop into a serious manufacturer, but its systems had not kept pace. Production was planned in spreadsheets maintained by one senior planner, inventory counts lived in a separate file, and purchasing reacted to shortages instead of anticipating them.
The symptoms were familiar: material stock-outs that halted production runs, over-purchasing of items already in stock, and no reliable answer to the question "can we take this order and deliver on time?"
What we did
We implemented an integrated ERP covering the full make-to-order flow: sales orders driving material requirements, bills of materials with routing, purchase planning based on real lead times, and barcode-based inventory moves on the floor.
- Discovery workshops mapped the actual production flow, including the exceptions.
- Item master and BOM data was cleaned and migrated from spreadsheets.
- Work orders and quality checkpoints were digitized on shop-floor terminals.
- Purchasing switched to demand-driven replenishment with supplier lead times.
The results
Planning that took a full day each week now happens in a fraction of the time, with the whole team working from the same live data. Material visibility ended surprise stock-outs, and management finally sees true production costs per order.