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What Volume Does To A Manufacturer That Isn't Ready For It
Everything might feel manageable at the scale you're running now, but waiting to upgrade your software platform until the tipping point adds unnecessary risk.
Capacity and downtime break first.
Managing load across your people and your machines is the first thing to go as volume rises, and downtime stops being an inconvenience to become the constraint.
Buying accuracy degrades in both directions.
Over-supply on some products and short supply on others, with cash tied up in the wrong stock.
BOM errors stop being local.
Bills of materials multiply and drift out of date. One wrong component cost quietly distorts every finished good sitting above it, and nothing looks obviously broken.
Subcontracting duplicates itself.
Without a single view of what's outsourced where, you end up with several subcontractors doing the same work and no clear picture of what it's costing.
Underneath all four is the same thing. Nobody is maintaining the source data, so costs and variations move without anyone knowing why or how to fix it.
The Six Problems We Solve for Manufacturers
When production, planning and costing all sit in the same system, you can see what's happening as it happens; instead of invisible cost blowouts you only find out about after a job’s done.
Production Variances
Today's Production Reality
A job is quoted at an hour and a half, but nobody tracks the steps on each run. A weld that should take 25 minutes takes an hour, and nobody knows it happened.
The DIY-ERP Correction
Production orders capture actual time and consumption against expected at every step, so variance surfaces by job, by process, by person and by machine.
Costings That Drift Out of Date
Today's Production Reality
Without full bills of materials, routings and machine centres in one place, true cost is an estimate. Component prices move all year, and nothing keeps up.
The DIY-ERP Correction
BOMs, routings and machine centres are configured correctly and maintained by your own Super User, so true cost stays current across material, labour, machine time, overhead and subcontract.
Planning on a Production Board
Today's Production Reality
Without integrated procurement and advanced planning, the schedule can't flex with real demand, and just-in-time stays out of reach because the right stock isn't there.
The DIY-ERP Correction
MRP (Material Requirements Planning) and master planning read inventory, open orders, forecasts and BOMs, then generate production and purchase orders with the right timing, tuned to your real lead times.
Month-End Consumption
Today's Production Reality
Raw materials get written off at month-end rather than consumed as they're used. An engine gets forgotten, and the system shows overstock while the floor is short.
The DIY-ERP Correction
Consumables flush automatically, expensive components are selected manually, and materials move into work in progress in the period they actually moved.
A Configuration That Doesn't Match How You Build
Today's Production Reality
Contract manufacturers need production runs under a project. Make-to-order changes components every order. Some businesses break one raw material into many.
The DIY-ERP Correction
Business Central covers project, make-to-order, make-to-stock, assemble-to-order and disassembly, configured to the way you build, so the cost of changing a component is visible.
Traceability Held in Filing Cabinets
Today's Production Reality
When a customer or an auditor asks where a batch went, the answer sits between a spreadsheet and a filing cabinet, while four departments hold four versions of the truth.
The DIY-ERP Correction
Lot and serial tracking follows materials through production into finished goods and on into Service Management, so a batch traces both ways in minutes.