Enterprise Resource Planning Platform
Implemented a comprehensive ERP solution that streamlined operations, reduced costs, and improved overall efficiency across multiple manufacturing plants.
![Enterprise Resource Planning Platform](data:image/svg+xml,%3Csvg xmlns="http://www.w3.org/2000/svg" viewBox="0 0 400 300"%3E%3C/svg%3E)
Key Results
Annual Savings
Efficiency
User Adoption
Integration Time
Inventory Accuracy
Productivity Gain
Case Study Overview
The Challenge
The client was struggling with disconnected legacy systems across 12 manufacturing plants, leading to data silos, inefficient processes, and lack of real-time visibility. This resulted in excess inventory costs, production delays, and difficulties in financial reporting and forecasting.
Our Analysis
Two consultants spent four weeks on the shop floor across the conglomerate's 12 plants before any architecture decisions were drawn:
- Plant-by-plant MES heterogeneity: Three different Wonderware versions and one home-grown MS-Access shop-router, each with its own work-order schema.
- Material master sprawl: 138,000 SKUs with overlapping part numbers and inconsistent UoM conversions, blocking any meaningful demand planning.
- Month-end close in 15 days: Inter-company eliminations were rebuilt by hand in Excel; auditors flagged manual journal volume in the prior SOX cycle.
- OSHA and ITAR exposure: Quality holds and ITAR-controlled exports were tracked outside the system, creating audit findings.
- Capacity ceiling on the legacy ERP: Original IBM AS/400 install was at 92% transaction-log utilization, with no realistic upgrade path.
Our Solution
We rolled out Oracle Fusion Cloud ERP with a plant-by-plant phased cutover: a canonical material master pushed via Oracle Integration Cloud, MES adapters that map Wonderware tags to Manufacturing Work Orders, ITAR-aware quality holds, and a Power BI close cockpit that compressed month-end inter-company eliminations from 15 days to 3.
The Results
The ERP implementation transformed the client's operations by eliminating data silos and automating key processes. Production lead times decreased by 35%, while inventory accuracy improved to 99%. Financial closing cycles were reduced from 15 days to just 3 days. The real-time visibility enabled proactive decision-making and improved resource allocation, resulting in a 43% increase in overall productivity and significant cost savings through optimized inventory and improved procurement.
Key Features & Components
- Integrated Manufacturing Resource Planning
- Advanced Inventory Management
- Supply Chain Optimization
- Financial Management & Reporting
- Human Resource Management
- Quality Control System
- Executive Dashboards & Analytics
- Mobile Access for Remote Management
Project Information
Client
Industry
Timeline
Services Provided
- ERP System Integration
- Process Reengineering
- Data Migration & Cleansing
- Custom Development
- Training & Change Management
Technologies Used
Project Gallery
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