"We wanted to make sure we took our time with the implementation and did it right. The biggest win for us has been the proper allocation of parts to jobs and real-time visibility of our manufacturing operations." Plant Manager
Background
Client/Company: Regional conveyor belt manufacturer specialising in telescopic conveyor systems
Industry: Industrial manufacturing equipment
Size: 20 employees across engineering, accounting, purchasing, and manufacturing departments
Challenge/Problem: The company was managing operations across multiple disconnected systems (E2 MFG for inventory, QuickBooks for accounting) which created data silos and inefficiencies. Their primary challenge was the lack of integrated visibility into inventory allocation for specific jobs, combined with manual production scheduling and limited real-time manufacturing status tracking.
Solution
Approach: Comprehensive on-premise Odoo ERP implementation covering manufacturing, inventory, purchasing, sales, and accounting modules with custom configurations for their complex multi-layer assembly processes.
Tools/Methods: The solution included custom bill of materials setup for 5-layer assembly structures, barcode scanning implementation, serial number management, and a hard allocation system preventing accidental spare parts sales.
Results
| Metric | Before | After | Improvement |
|---|---|---|---|
| Systems Used | 3 separate systems | 1 integrated ERP | 67% reduction |
| Inventory SKUs Tracked | 10,000+ (fragmented) | 10,000+ (centralised) | 100% visibility |
| Data Entry | Dual entry required | Single entry | 50% time savings |
| Job Tracking | Manual processes | Real-time monitoring | Complete transparency |
Qualitative Benefits: Enhanced production scheduling accuracy, improved job costing through precise labour tracking, and streamlined change management through the phased implementation approach.
Key Takeaway
A patient, methodical approach to ERP implementation enabled seamless integration of complex custom manufacturing processes whilst maintaining operational continuity.