Manufacturing ERP with Production Planning

A phased ERP rollout covering purchase, stores, production, quality and dispatch for a three-plant auto component manufacturer.

Client

Confidential - Auto Components

ERP

Duration

44 weeks

Delivered

2023

The challenge

Three plants ran independent spreadsheets for production planning and inventory. Stock accuracy was around 70 percent, leading to both stock-outs on the line and excess working capital tied up in slow-moving items. Costing was estimated rather than calculated.

What we built

We implemented ERP module by module over eleven months, beginning with stores and inventory where the pain was greatest. Production planning covers BOM explosion, job cards, machine scheduling, subcontracting and work-in-progress tracking with barcode scanning at each stage.

Quality checkpoints are enforced in the workflow - material cannot move to the next stage without inspection sign-off. Actual costing rolls up material, labour and overhead per batch, giving true margin visibility per part number.

The result

Inventory accuracy reached 98 percent within two quarters. Working capital tied up in raw material fell by roughly 23 percent. Management now sees true per-part margins, which led to renegotiating or exiting several loss-making lines.