One ERP for an oil-seal plant, with every batch traceable to its vendor
Manufacturing
The challenge
An oil-seal manufacturer ran purchase, production and quality in four separate applications, each with its own login and its own copy of the same items, materials and customers. When a customer queried a shipped batch, nobody could say which vendor's material had gone into it.
What we built
We consolidated the four applications into one ERP covering purchase, production, quality and inventory, and rebuilt the material ledger so every batch links back to the lot it consumed, the goods receipt that lot arrived on, the inspector who approved it and the vendor who supplied it. Forty-seven screens sit behind a single sign-in, with a permission model the server enforces rather than the browser. The plant's existing pre-dispatch inspection application kept its exact URL, its behaviour and its production data throughout — nothing was migrated, and the two ran side by side on one database until the plant chose to switch.
The result
Every production batch is now traceable to the vendor that supplied its material, whichever screen created it, and a batch that cannot be sourced from material actually in stock is refused rather than created untraceably. A trace that previously returned nothing at all for twenty-one of twenty-two batches now answers all four audit questions — which material, from which receipt, approved by whom, from which vendor — in a single request. Stock and lots became one ledger instead of two, checked against an invariant on every deployment. Four sign-ins became one, and the inspection application the plant ships certificates from was never taken offline.