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Modernization of Legacy Manufacturing Systems with Scalable ERP Integration
  1. case
  2. Modernization of Legacy Manufacturing Systems with Scalable ERP Integration

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Modernization of Legacy Manufacturing Systems with Scalable ERP Integration

orases.com
Manufacturing
Consumer products & services
Medical

Current System Limitations and Operational Challenges

Community Products relies on a legacy Windows-based system with poor data visibility, manual spreadsheet-driven workflows, and excessive dependency on process engineers' institutional knowledge. This creates scalability issues, prolonged onboarding for new hires, and inefficiencies in managing 42,000+ parts and 20,000+ workflows across distributed manufacturing facilities.

About the Client

Manufacturer of maple furniture/toys for early childhood settings and adaptive equipment for individuals with disabilities, operating multiple factories with specialized engineering teams.

Strategic Modernization Goals

  • Replace legacy system with a modular, cloud-hosted ERP solution
  • Reduce dependency on specialized process engineer knowledge
  • Improve cross-facility workflow visibility and data accessibility
  • Decrease onboarding time for new team members by 50%
  • Enable seamless scalability for future workflow/part growth

Core System Capabilities

  • Interactive visual workflows showing part manufacturing journeys
  • User-friendly interface for workflow creation/editing
  • Real-time synchronization with legacy PMAN/MES systems
  • Work center/process management dashboard
  • Modular architecture for incremental feature expansion

Technology Stack Requirements

Azure cloud hosting platform
Modern web framework (.NET/React/Node.js)
Relational database (SQL Server/PostgreSQL)
API-first architecture

System Integration Needs

  • Legacy PMAN system synchronization
  • MES (Manufacturing Execution System) connectivity
  • Active Directory authentication

Operational Requirements

  • 99.9% system uptime SLA
  • Support for 500+ concurrent users
  • Role-based access control (RBAC)
  • 2000+ workflow updates per hour capacity
  • Automated system backups with 15-minute RPO

Expected Business Transformation

Implementation of the modern ERP module will reduce process engineering dependency by 70%, enable 30% faster workflow execution through visual tools, and support 2x growth in managed workflows within three years. The solution will standardize manufacturing processes across facilities while maintaining zero developer turnover through intuitive design and modular maintainability.

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