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Manufacturing floor

Manufacturing ERP Modernization

Transforming a mid-sized food processor with unified operations and real-time dashboards.

Client Overview

Industry: Food Processing | Region: East Africa | Size: 300+ employees | Scope: 6 months

A mid-sized food processing company operating 5 regional warehouses with fragmented systems across finance, inventory, and production. Annual turnover ~$15M with growth ambitions to regional expansion.

The Challenge

  • Disconnected systems: Finance on QuickBooks, inventory on spreadsheets, production manual tracking
  • High waste: 12% material loss due to poor stock visibility
  • Slow reporting: 12-day month-end close process
  • Stockouts & overstock: Inability to predict demand across regions
  • Compliance risk: No audit trail for regulatory requirements

Solution

We implemented a modular ERP system with the following components:

  • Financial module: Automated GL, AR/AP, cost allocation by warehouse
  • Inventory: Real-time stock tracking with barcode scanning, FOQ calculation, cycle counting
  • Production: MRP with work order management and material consumption tracking
  • Dashboards: Plant-level KPI boards for production managers, executive dashboards for leadership
  • Integration: E-commerce sync, supplier portal for PO tracking

Training & Change: 3-week rollout with hands-on training for all departments and a dedicated support team for first 3 months.

Results

97%
Inventory Accuracy
4 days
Month-End Close
8%
Waste Reduction
$340K
Annual Savings

Technology Stack

Dolibarr ERP PostgreSQL Node.js API Power BI Zebra Scanners Docker

Learnings & Best Practices

  • Phased rollout: Started with finance + key inventory locations before full deployment
  • Data cleansing: 3-week effort to reconcile historical inventory and GL balances
  • Executive sponsorship: CEO-level support accelerated adoption across production teams
  • Customization restraint: Kept customizations minimal to reduce maintenance burden

Client quote: "Before this project, we were flying blind. Now we know exactly where every inventory item is, and our managers can make data-driven decisions in minutes instead of days."

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