Custom ERP for Manufacturing
Unified ERP Replacing 6 Disconnected Systems
One ERP replacing 6 disconnected systems — zero data discrepancies, 45% lower operational costs.
Who We Built This For
Meridian Manufacturing is a 350-employee manufacturing unit in Germany that had been running 6 disconnected systems across production, HR, inventory, procurement, quality control, and finance. Each system operated independently, requiring constant manual reconciliation and causing daily data sync failures that disrupted operations.
What We Set Out to Build
Meridian Manufacturing needed to consolidate 6 separate, disconnected systems into a single, unified ERP — without disrupting ongoing production while the transition happened. The fragmented systems had created a daily cycle of manual data reconciliation, where production figures, inventory counts, and financial numbers frequently didn't match across departments, undermining confidence in the data itself.
The new ERP was built around a single source of truth for every operational data point: production planning feeds directly into inventory consumption, procurement orders update stock levels automatically, and quality control results are tied directly to the production batches they apply to. This eliminated the manual cross-checking that had previously consumed significant administrative time every single day.
HR and payroll were brought into the same unified system, connecting workforce scheduling directly to production planning so that staffing levels could be adjusted based on real production demand. Financial reporting pulls live from every operational module, replacing what had been a slow, error-prone month-end consolidation process with real-time financial visibility — cutting production reporting time to a third of what it had been and eliminating data discrepancies entirely.
Project Facts
Tech Stack
What Needed to Be Solved
Meridian Manufacturing's 350-employee unit ran 6 disconnected systems across production, HR, inventory, procurement, quality control, and finance — causing daily data sync failures, inventory discrepancies, and a constant administrative burden of manual reconciliation between systems that should have shared the same underlying data.
Production, inventory, procurement, and finance data lived in 6 separate systems with no automatic synchronisation, requiring constant manual reconciliation
Daily data sync failures between systems caused inventory discrepancies that disrupted production planning and procurement decisions
HR and payroll operated independently from production planning, making it difficult to align staffing levels with actual production demand
Quality control results were recorded separately from production batch data, making it hard to trace quality issues back to their root cause
Month-end financial reporting required manually consolidating data from all 6 systems, a slow and error-prone process
No single source of truth existed for any operational metric, undermining confidence in reported numbers across departments
Inside the Platform
Every module is purpose-built to replace a standalone tool — unified in one workspace.
- Real-time production schedule management
- Automatic inventory consumption tracking
- Capacity planning across production lines
- Batch-level traceability
- Demand-driven scheduling adjustments
- Live stock-level tracking
- Automated procurement triggers
- Supplier order management
- Zero-discrepancy stock reconciliation
- Multi-warehouse visibility
- Batch-linked quality inspection records
- Defect tracking & root cause analysis
- Compliance documentation generation
- Quality trend reporting over time
- Non-conformance workflow management
- Workforce scheduling tied to production demand
- Automated payroll processing
- Real-time financial reporting
- Cross-module cost allocation
- 3x faster production-to-finance reporting
Everything in One Workspace
Single Source of Truth
Every operational data point — production, inventory, finance — lives in one unified system, eliminating cross-system discrepancies entirely.
Production Planning
Real-time production scheduling that automatically consumes inventory and adjusts to demand without manual cross-checking.
Automated Procurement
Stock-level triggers automatically generate procurement orders, keeping inventory aligned with real production needs.
Batch-Linked Quality Control
Quality inspection results are tied directly to production batches, enabling fast root-cause tracing for any defect.
Demand-Linked Workforce Planning
HR and payroll connect directly to production planning, aligning staffing levels with actual production demand.
Real-Time Financial Reporting
Financial reports pull live from every operational module, replacing slow month-end manual consolidation.
3x Faster Reporting
Production reporting that previously took days now completes in a third of the time, thanks to unified live data.
Containerised Architecture
Built on Docker for reliable, consistent deployment across the manufacturing unit's infrastructure.
How We Built It
System Audit & Data Model Unification
Audited all 6 existing systems to map their data models, then designed a single unified schema covering production, HR, inventory, procurement, quality, and finance.
Production & Inventory Core
Built the production planning and inventory management core, linking production schedules directly to automatic inventory consumption and procurement triggers.
Quality Control Integration
Developed the quality control module with batch-level traceability, linking inspection results directly to the production batches they apply to.
HR, Payroll & Financial Reporting
Built the HR and payroll module connected to production demand, and the real-time financial reporting system pulling live from every operational module.
Migration & Zero-Downtime Rollout
Migrated data from all 6 legacy systems and rolled out the unified ERP with a phased approach to avoid disrupting ongoing production.
Full Scope of Work
Audited 6 disconnected legacy systems and designed a single unified data schema replacing all of them
Built a production planning module with automatic inventory consumption and capacity tracking
Developed automated procurement triggers based on real-time stock levels, eliminating manual reordering
Built a quality control module with batch-level traceability linking inspections to production data
Integrated HR and payroll directly with production planning to align staffing with demand
Developed real-time financial reporting pulling live from every operational module
Migrated all historical data from 6 legacy systems with zero data discrepancies post-migration
Deployed the ERP on a containerised Docker architecture for reliable, consistent operations
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