Multi-Plant ERP Consolidation for a Precision Equipment Manufacturer
The manufacturer struggled with fragmented legacy ERP systems across four production sites, causing operational blind spots and inventory discrepancies. CYVERRA consolidated these disparate platforms into a unified modern ERP instance with real-time shop-floor integration and harmonised global supply chain workflows.
Mid-tier European precision machinery and industrial equipment manufacturer
- -24%
- Inventory carrying costs
- -42%
- Production scheduling cycle
- from 11 days to 3 days
- Month-end financial close
- 99.4%
- BOM reconciliation accuracy
The Challenge
Operating across four production facilities in Western and Central Europe, the client relied on legacy, disconnected ERP installations that had diverged over a decade of incremental customisation. This fragmentation created severe operational silos: production schedulers lacked real-time visibility into cross-site raw material availability, leading to excessive safety stock buffering and frequent dispatch delays for high-specification machinery components. Material requirement planning (MRP) runs required overnight batch processing, leaving operations teams unable to adapt dynamically to supplier disruptions or mid-stream engineering change orders (ECOs). In addition, disparate master data schemas across plants caused persistent reconciliations between finance, procurement, and bill of materials (BOM) management, lengthening month-end financial reporting cycles and obscuring true production unit margins.
Our Approach
CYVERRA architected and delivered a centralised enterprise ERP platform built on SAP S/4HANA Cloud, harmonising core manufacturing, financial, and supply chain processes across all operational entities. The engagement began with establishing a single source of truth for global master data, consolidating over 45,000 component SKUs and standardising multi-level BOM structures across all operating units. To bridge the gap between planning and shop-floor execution, CYVERRA deployed an event-driven integration layer using Azure Integration Services and Apache Kafka. This architecture interfaced directly with distributed Manufacturing Execution Systems (MES) and industrial IoT telemetry gateways, enabling automated work-order tracking, live machine downtime capture, and immediate material consumption postings. CYVERRA implemented automated validation pipelines to verify quality compliance and batch traceability before automated goods-issue generation. A phased cutover strategy by production facility ensured continuous manufacturing operations. Change management was supported through modular role-based training programs, pre-configured dashboard templates for plant managers, and automated regression testing suites that validated end-to-end order-to-cash and procure-to-pay processes ahead of each deployment milestone.
The Outcome
The consolidated ERP platform unified operational visibility across all four manufacturing sites, enabling centralised procurement and agile cross-plant load balancing. Automated MRP calculations now run continuously against real-time production telemetry, reducing lead times on custom assembly builds and significantly curbing rush-freight expenditures caused by component shortages. Standardised financial and inventory workflows eliminated cross-entity reconciliation overhead, giving executive leadership precise visibility into unit-level gross margins and asset utilisation across the enterprise. The modernised data architecture also established an auditable digital thread from component procurement to final inspection, ensuring seamless adherence to stringent industrial safety and quality standards.
Technology used
- SAP S/4HANA
- Azure Integration Services
- Apache Kafka
- Power BI
- PostgreSQL
- Terraform
Consolidating our plant operations onto a single modern ERP platform gave us real-time inventory precision and dramatically shortened our manufacturing lead times.