From Chaos to Control: A Custom ERP for a Mid-Market Manufacturing Leader
Industry Discrete Manufacturing
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$10B+ Client Revenues
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12+ Successful Years
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1000+ IT Ninjas
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5000+ Projects
Client's Testimonial
"The system Developers.dev built for us is the central nervous system of our entire operation. For the first time, we have real-time visibility from order entry to final shipment. Our production planning is now data-driven, not guesswork. This wasn't just a software project; it was a fundamental business transformation. We reduced our lead time by 25% within the first year."
Mark Johnson, COO
Client Overview
Our client is a US-based, $120M ARR manufacturer of high-precision aerospace components. For years, they operated on a disjointed system of an outdated accounting package, countless Excel spreadsheets, and several standalone applications for inventory and shop floor management. This created massive inefficiencies, including frequent production delays due to inaccurate inventory data, difficulty in tracking job costs, and an inability to provide customers with reliable delivery timelines. The leadership team knew they couldn't scale or compete effectively without a single, unified source of truth.
Problem
The client's fragmented system made it impossible to get an accurate, real-time view of their operations. This lack of visibility led to excessive inventory carrying costs, missed delivery deadlines, and an inability to accurately quote new projects, directly impacting profitability and customer satisfaction.
Key Challenges
Data Silos
Critical information was trapped in different systems, leading to constant manual reconciliation and errors.
Inaccurate Inventory
No real-time tracking of raw materials or work-in-progress (WIP), causing production stoppages and over-ordering.
Lack of Job Costing
Inability to track the true cost of each production run, making it difficult to price competitively and identify unprofitable jobs.
Manual Reporting
The finance and operations teams spent dozens of hours each week manually compiling reports, which were often outdated by the time they were completed.
Our Solution
Developers.dev partnered with the client to design and build a custom, cloud-based ERP from the ground up, focusing on the specific needs of a high-precision manufacturing environment.
Unified Operations Hub
We created a central system that integrated sales orders, inventory management, production scheduling, quality assurance, and shipping logistics.
Real-Time Inventory Tracking
We implemented a barcode-based system for tracking materials from receiving through every stage of production to final shipment.
Advanced Production Scheduling
We developed a module that allowed planners to schedule jobs based on machine availability, material stock, and labor capacity, optimizing throughput.
Automated Job Costing & Reporting
The system automatically tracked all material, labor, and overhead costs for each job, providing real-time profitability analysis and automated financial reports.
Implementation and Execution
Deep-Dive Discovery
Our business analysts spent two weeks on-site, mapping every workflow from the shop floor to the finance department.
Agile Development Sprints
We used a phased approach, delivering the core inventory and order management modules first to provide immediate value.
User-Centric Design
We worked closely with the client's shop floor staff to design an intuitive, tablet-friendly interface that minimized training time.
Seamless Data Migration
Our data engineering team carefully planned and executed the migration of decades of historical data from legacy systems.
Rigorous QA Testing
Our QA pod conducted extensive testing, including simulating peak production loads, to ensure the system was robust and reliable.
Phased Rollout & Training
We rolled out the system department by department, providing hands-on training to ensure smooth adoption.
Positive Outcome
25% Reduction in Lead Time
Optimized scheduling and material management significantly shortened the time from order to delivery.
99% Inventory Accuracy
Real-time tracking eliminated stockouts and reduced excess inventory carrying costs by 18%.
15% Improvement in Gross Margin
Accurate job costing allowed the client to refine pricing and focus on the most profitable products.
50+ Hours Saved Weekly
Automation of manual reporting freed up key personnel to focus on strategic analysis and process improvement.
Why Choose Us
Deep Domain Expertise
We understood the nuances of discrete manufacturing.
Outcome-Oriented Partnership
We focused on solving their business problems, not just delivering software.
Agile & Iterative
We delivered value quickly and adapted to feedback.
CMMI Level 5 Process
Our mature processes ensured a high-quality, predictable outcome.
Full IP Ownership
The client now owns a valuable, proprietary asset.
Seamless Integration
We built a system that works perfectly within their existing tech landscape.
Data-Driven Approach
We ensured every decision was backed by clean, reliable data.
Transparent Communication
The client had full visibility into our progress at all times.
Post-Launch Support
We continue to support and enhance the system to meet their evolving needs.
Conclusion
By replacing a chaotic collection of disparate systems with a single, intelligent ERP, the client transformed their operations from a competitive disadvantage into a powerful engine for growth. They now have the control, visibility, and data-driven insights needed to thrive in a competitive market.