ERP Implementation for APG – Auto Parts General, A Manufacturing Concern.

Client Profile

Company: APG Autos Ltd.
Industry: Automotive Parts Manufacturing
Challenge: Disconnected systems (inventory, finance, HR), manual data entry, inefficiencies in supply chain, and lack of real-time analytics.

Objective

Implement an ERP system to integrate operations, automate workflows, and improve decision-making.

ERP Planning & Development

1. Requirement Analysis

  • Conducted stakeholder interviews to identify pain points.
  • Key needs:
  • Inventory & procurement tracking
  • Production scheduling
  • Financial management (invoicing, payroll)
  • Supplier & customer relationship management (CRM & SRM)

2. Vendor Selection

  • Evaluated Odoo, Oracle ERP Cloud, and Microsoft Dynamics 365.
  • Chose Bespoke MeteSys ERP with MS-Sql & .Net framework (best fit for manufacturing scalability).

3. Customization & Development

  • Developed modules for:
  • Production Planning (MRP – Material Requirements Planning)
  • Supply Chain Management (SCM)
  • Finance & Accounting
  • Integrated with existing IoT sensors for real-time machine monitoring.

Installation & Configuration

1. System Setup

  • Deployed on cloud (AWS) for scalability.
  • Configured:
  • User roles (admin, production manager, finance team)
  • Workflow automation (purchase approvals, invoice processing)
  • Dashboards for real-time KPIs (OEE, inventory turnover)

2. Data Migration

  • Migrated legacy data (SQL → SAP HANA) with validation checks.

3. Testing (UAT – User Acceptance Testing)

  • Conducted 3 test cycles with key departments.
  • Fixed bugs in reporting and purchase order automation.

Implementation & Go-Live

1. Phased Rollout

  • Pilot Phase: Implemented in one production plant.
  • Full Deployment: Scaled to all 5 plants in 3 months.

2. Training & Change Management

  • Conducted workshops for 200+ employees.
  • Created user manuals & video tutorials.

3. Post-Implementation Support

  • 24/7 helpdesk for first 3 months.
  • Performance tuning for faster report generation.

Use Case: Inventory Optimization

Problem:

  • Stockouts and overstocking due to poor demand forecasting.

ERP Solution:

  • Automated Reordering: MRP triggers purchase orders when stock reaches threshold.
  • Supplier Integration: Real-time updates from vendors reduce lead time.

Results:

+ 30% reduction in excess inventory
+ 20% improvement in order fulfillment speed
+ Reduced manual errors by 95%

Long-Term Benefits

✔ Operational Efficiency – Streamlined workflows across departments.
✔ Cost Savings – Reduced manual labor and inventory waste.
✔ Data-Driven Decisions – Real-time analytics for better planning.
✔ Scalability – Supports business expansion into new markets.

Conclusion

The ERP implementation transformed XYZ Manufacturing’s operations by integrating siloed systems, automating workflows, and improving inventory management. The project’s success highlights the importance of structured planning, user training, and phased deployment in ERP adoption.

Lessons Learned:

  • Involve end-users early to ensure smooth adoption.
  • Continuous monitoring post-launch is critical for optimization.

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