ERP rollout across 3 plants in under 90 days
The Business Challenge
A prominent Tier-2 auto parts manufacturer operating 3 manufacturing units struggled with operational visibility. Production schedules, warehouse counts, employee shifts, and corporate finance were managed on disconnected Excel spreadsheets.
This siloed approach caused production delays, raw material waste, and audit bottlenecks. Preparing month-end financial reviews required 10 days of manual data collation, delaying critical operational decisions.
Our Engineering Approach
We deployed a custom instance of ZerpAI ERP across all three facilities. A unified database schema was mapped on Postgres to centralize data from production floors, HR rosters, and financial accounts.
We engineered specific modules for raw materials tracking, real-time machine uptime logs, and cross-plant inventory sync. Our migration team engineered automated cleaning scripts to ingest and format 12 years of historical production records within a strict 90-day window.
Business Outcomes & Impact
The entire ERP system went live across all three facilities within 88 days, beating the 90-day target.
Month-end financial close-out times dropped from 10 days to under 4 hours due to real-time general ledger integrations. Material waste dropped by 18% in the first quarter of rollout due to tighter production controls, improving plant margins by 4.2%.
Interested in similar outcomes?
Contact our engineering team to explore architectures and automation systems that fit your operations.
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