ERP Implementation for Manufacturers: How a $25M Electronic Component Company Scaled in 90 Days
- Elliott Clark Consulting
- May 20
- 4 min read
Updated: May 29
From paper chaos to real-time control with Microsoft Dynamics 365 Business Central
Are Sticky Notes Running Your Operation?
This $25 million electronic component manufacturer was thriving in the market. Their precision components powered everything from medical devices to smart sensors. But behind the scenes?
Operations were stuck in the past.
“We were managing a multi-million-dollar supply chain on sticky notes, clipboards, and gut instinct,” the CEO confessed. “And we were paying for it—every day.”
The True Cost of Paper-Based Processes in Manufacturing
On the surface, things looked fine. Orders went out, the company grew, and customers were happy.
But internally, processes were chaotic.
Inventory was managed with manual counts and paper bin cards.
Production schedules were written on whiteboards that changed hourly.
Purchase orders were printed, filed in binders, and emailed manually.
Invoices were created from spreadsheets… often days late.
The warehouse team relied on sticky notes taped to shelves.
Every mistake led to lost time and rising costs:
$12,000/month in overnight freight to cover missing inventory.
Stockouts on common parts, even with hundreds of SKUs on hand.
A 12-day month-end close requiring three departments to reconcile data manually.
A failed audit due to inaccurate BOM tracking.
“We didn’t have one version of the truth,” the CFO said. “We had three—and none of them matched.”
The Breaking Point
They nearly lost a six-figure order when they couldn’t fulfill a rush job for a critical medical device OEM. The issue? A single part—worth $0.38—was out of stock.
Nobody knew. There was no automated reorder point. The spreadsheet hadn’t been updated. The supplier had a 14-day lead time. They had to overnight the part at $278 just to keep the order alive.
That was the final straw.
Starting the ERP Implementation Journey
They turned to Elliott Clark Consulting with one clear goal: Fix the foundation fast—and build a platform that could scale.
We recommended Microsoft Dynamics 365 Business Central, a cloud-based ERP built for manufacturers who need control, visibility, and flexibility without massive overhead.
They signed on for our Packaged Business Central Implementation—an agile, proven approach focused on results without disruption.
Our 4-Phase ERP Implementation for Manufacturers
We don’t start with software. We start with people and processes. The best ERP in the world won’t fix broken workflows.
Phase 1: Spark – Understanding the Real Problems
We conducted process walkthroughs across purchasing, inventory, production, and finance. Pain points were mapped visually, highlighting redundant work, version control issues, and risks from paper-based tracking.
During this phase, we identified significant inefficiencies:
$30K+/year in wasted labor due to manual processes.
Repetitive data entry across three disconnected systems.
Zero real-time data for decision-making.
We set clear priorities: stabilize inventory, reduce purchasing chaos, and ensure accurate financials.
Phase 2: Navigate – Focus on the Fundamentals
We implemented Business Central’s core capabilities:
Inventory Management: real-time inventory, including item tracking, reorder points, and cycle counts.
Purchasing Workflows: with approval hierarchies and vendor lead time automation.
Production Scheduling: using routings and work centers.
Financial Management: real-time P&L, cash flow statements, and dimensional reporting.
They eliminated:
Spreadsheets
Manual rekeying
Whiteboards
Paper purchase orders
Phase 3: Shape – Tailoring to Their Operation
We didn’t customize it—we configured it based on best practices for electronic component manufacturing.
Highlights included:
Defining critical item attributes for reporting and clear planning parameters.
Setting up units of measure across component types (resistors, ICs, housings, etc.).
Building dashboard views for procurement, inventory, and financial KPIs.
Defining a clear planning process for low-stock and long-lead items.
Creating a flexible structure for future warehouse expansion.
We also cleaned up years of legacy data and migrated only what mattered.
Phase 4: Activate – Go Live Without Disruption
They went live in just 90 days. Training was hands-on, role-based, and aligned to each department’s needs.
“I expected go-live to be stressful,” the Operations Manager shared. “But it felt like flipping a switch—we were ready.”
Daily operations continued uninterrupted. Orders shipped, teams adjusted quickly, and within weeks, the change was obvious.
The Results: 60 Days After ERP Go-Live
The benefits were remarkable:
Expediting Costs Down 85%: Inventory visibility led to accurate ordering, fewer surprises, and lower freight bills.
18% Reduction in Inventory Carrying Costs: Less overstock meant no more hoarding “just in case.” Planning became data-driven.
Dashboards Replaced Whiteboards: Leadership now has live views of cost, cash flow, capacity, and KPIs. No more calling around for answers.
Month-End Close in 3 Days Instead of 12: Integrated financials and clean data removed friction. Confidence in the numbers has never been higher.
Employee Efficiency Up 30%: Warehouse staff now focus on fulfillment, not on chasing paper. Finance isn’t burdened by manual reconciliations. Time is spent moving forward—not cleaning up.
“It’s like we’ve gone from fog to high-beam headlights,” said the CEO. “We finally see what’s going on—and what’s possible.”
What’s Next: Phase 2 Is Already Underway
With a strong ERP foundation in place, the company is now preparing for Phase 2:
Warehouse Barcode Scanning: To streamline receiving, picking, and job tracking.
Fixed Asset Tracking: To manage tools, machines, calibration, and depreciation.
Advanced Warehousing: To enable bin-level inventory, directed put-away, and better space utilization.
They’re no longer reacting; they’re building a modern, connected operation—and using Business Central as their backbone.
Why It Worked
The success stemmed from not over-customizing or overthinking. They didn’t wait until everything broke down.
They chose a quality partner that understood their business. They followed a smart, structured ERP implementation plan for manufacturers—focused on quick wins, operational clarity, and scalable growth.
What Could This Mean for Your Business?
What if your team stopped chasing paper and started planning with confidence? What if you could stop wasting time on manual fixes and start scaling without fear? What if your ERP could pay for itself in the first quarter?
Let’s Get You There
Process & Profitability Workshop—with three options, you have a choice. We’ll help uncover hidden costs, inefficiencies, and risks and show you what modern manufacturing looks like.
Book a Business Central Demo—see the dashboards. Watch the workflows. Imagine what’s possible.
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