ManufacturingPakSteel Industries7 months, 3 phases
ERP rollout that closed month-end in days, not weeks
A 400-employee steel manufacturer ran finance, inventory, and HR on disconnected spreadsheets. A phased custom ERP rollout unified operations and cut month-end closing from three weeks to four days.
- month-end closing time
- 3 weeks → 4 days
- inventory accuracy across 3 warehouses
- 100%
- hours of production downtime during rollout
- 0
The Challenge
- Finance, production, and HR each maintained separate spreadsheets that never reconciled with each other.
- Month-end closing took three weeks of manual consolidation — and the numbers were still disputed.
- The plant floor ran 24/7; any rollout that stopped production was unacceptable.
The Solution
- A three-phase rollout: inventory and procurement first, then production tracking, then finance and HR integration.
- Each phase ran in parallel with the old process until daily reconciliation proved the new system accurate.
- Mobile terminals on the shop floor replaced paper job cards, feeding production data into costing in real time.
- Role-based training and a two-week help desk desk at each go-live — the old spreadsheets were retired for good.
“The phased plan was the difference. Every go-live was boring — which is exactly what we asked for.”
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