Manufacturing ERP Implementation
End-to-end ERP for a 500-employee manufacturer — from spreadsheets to real-time visibility.
Year
2024
Duration
8 months
Team
7 engineers
Industry
Manufacturing
The Challenge
What was broken.
A 500-employee garment manufacturer was running procurement, inventory, production, payroll, and finance across 14 disconnected spreadsheets and two legacy tools. Month-end close took 12 days. Managers had no live view of production floor status. Inventory was overstocked by an estimated 35% due to double-ordering and poor visibility. Finance was reconciling manually across six Excel files, introducing errors that took weeks to trace.
The Solution
What we built.
We built a unified ERP covering the full operational lifecycle: procurement with supplier management, production floor tracking with job cards and shift scheduling, a real-time inventory module with FIFO costing, HR and payroll compliant with Bangladesh labour law, and a finance module with a full chart of accounts. A role-based dashboard gave each department head a live operational view. The system was rolled out in phases over eight months to avoid production disruption.
Estimated annual savings of $180,000 in operational overhead within the first year. Finance team headcount for closing work reduced from 4 FTEs to 2.
Results
Measured outcomes.
- ✓Month-end close reduced from 12 days to 2 days
- ✓40% lower inventory holding costs
- ✓Real-time production floor visibility across 3 shifts
- ✓Eliminated 6 manual reconciliation spreadsheets
- ✓Payroll processed 500 employees in under 2 hours
- ✓Supplier lead time visibility improved order planning by 3 weeks
Tech Stack
More Work
Other case studies.
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