The company makes $165M in revenue from three plants and 210 CNC machines. Two plants share an ERP installed in 2013, carrying 380 customizations and out of vendor support since 2024. The third, acquired in 2021, still runs its own package. Only plant 1 has a manufacturing execution system, so 35% of machines report live data. IT and network outages stopped production for 46 hours last year. Month-end close takes 11 working days. Aerospace customer security audits have 14 major findings open, with a deadline of late 2028. IT spends $3.1M a year, 84% of it keeping existing systems running, with a team of 14.
Challenges- Two ERPs and three item masters mean a part has different numbers in each plant, work cannot be moved between plants without rekeying, and finance consolidates in spreadsheets.
- Plant networks are flat. Machine controllers, office PCs and guest wifi share one network in two plants, which is the main finding in customer security audits and the cause of the longest outage last year.
- Lot traceability depends on paper travelers in two plants. Building the full genealogy for a customer complaint takes about six hours, and medical device customers now expect it the same day.
We will focus on- Resilience and security first, because an unsupported ERP on an unsegmented network is the largest risk to revenue.
- One ERP template for all three plants, implemented with standard processes and the smallest plant first.
- Machine connectivity and manufacturing execution in every plant, so that OEE and lot history come from the machines and not from clipboards.
We will not- Upgrading the 2013 ERP in place. It is cheaper for two years, but it keeps the customizations and leaves plant 3 separate.
- Predictive maintenance and machine learning on spindle data. The plants asked for it, but it waits until all machines are connected and two years of data exist.
- A custom customer portal for order status. Customers will get scheduled reports from the new ERP until the rollout is complete.