Custom ERP System Development for Manufacturing Operations Optimization

The client currently relies on an off-the-shelf ERP solution that underutilizes its capabilities, handling only 5% of day-to-day operations while requiring extensive manual efforts (e.g., PDF-based reports and paper time cards) for the remaining functions. Additionally, the existing system has limited real-time data access, slow support response times, and fragmented workflows that hinder productivity and decision-making.

Operational processes are heavily burdened by manual data entry, delayed reporting, and disconnected systems, leading to inefficiencies and increased labor costs.

A mid-sized manufacturing company seeking to streamline workflows, improve real-time reporting, and integrate accounting processes for enhanced operational efficiency.

• Develop a requirements-based, lightweight ERP that matches specific operational needs without unnecessary features.
• Implement real-time reporting capabilities accessible directly within the system to eliminate PDF exports and manual data handling.
• Integrate electronic time tracking to replace manual paper timesheets, aiming to save over $30,000 annually in administrative costs.
• Design an intuitive work order flow with a step-by-step wizard, draft-saving, and user-specific focus areas to improve data completeness and usability.
• Create middleware to enable seamless two-way data synchronization with existing accounting software (e.g., QuickBooks) for accurate job costing, invoicing, payroll, and bill payments.
• Iterate system design based on user feedback, incorporating process improvements such as visual data presentation adapted to actual workflow preferences.
• Ensure system scalability, security, and performance to support future growth and compliance requirements.

• Customizable, requirement-driven system architecture focused solely on essential functionalities.
• Real-time analytics dashboards replacing static PDF reports for immediate decision-making.
• Integrated electronic time tracking system to replace manual paper-based timesheets and reduce associated costs.
• Reorganized work order flow split into multiple focused screens with wizard navigation, draft saving, and step-by-step guidance.
• Iterative design process with multiple revisions and user testing to optimize usability and workflow efficiency.
• Data visualization adapted to user preferences, including fallback views such as concise filtered tables over complex Gantt charts.
• Middleware enabling two-way data synchronization with the existing accounting system for comprehensive job costing, invoicing, and payroll management.

• Accounting software (e.g., QuickBooks or equivalent) via custom middleware for two-way synchronization
• Internal systems for time tracking and work order management
• Reporting tools or data visualization components

• Scalability to support future business growth and increased user load
• Performance metrics ensuring real-time reporting and efficient data processing
• Data security standards compliant with industry best practices
• User-friendly UI with proven reduction in workflow complexity
• System availability with minimal downtime to support manufacturing operations

The implementation of a tailored ERP system is expected to significantly improve operational efficiency, reduce manual labor costs by over $30,000 annually through electronic time tracking, and enhance data accuracy with real-time reporting. User feedback-driven iterative design will lead to higher user adoption and satisfaction, while seamless integrations will support more accurate job costing, invoicing, and payroll, ultimately enabling the client to scale operations more effectively.