Summary: A US-based industrial manufacturer with $200M+ annual revenue was running a 15-year-old on-premise ERP system. The system was unreliable, impossible to integrate with modern tools, and required a team of 6 just to keep it running. Management knew they needed to modernise, but feared the operational risk of replacing a system that touched every department.
Expedite Software Services built a modern, cloud-native ERP platform tailored to the client's manufacturing workflows — migrating 15 years of data and 400+ users with zero downtime.
Retire a 15-year-old on-premise ERP and replace it with a modern, cloud-native platform tailored to manufacturing.
Migrate 15 years of transactional data and 400+ active users without disrupting daily manufacturing operations.
Automate manual processes across procurement, production planning, inventory management, and financial reporting.
Provide executive dashboards with real-time KPIs across production, inventory, sales, and financial performance.
Open API architecture to integrate with CRM (HubSpot), e-commerce (Shopify B2B), and IoT sensors on the factory floor.
Platform designed to support growth from 1 to 4 manufacturing plants over the next 5 years.
Java (Spring Boot), PostgreSQL, Apache Kafka, Elasticsearch
Angular 16, TypeScript, PrimeNG, responsive dashboards
AWS (EKS, RDS, MSK, S3, Redshift), Terraform, Docker
Apache Spark, Redshift, QuickSight, custom BI dashboards
REST APIs, GraphQL, Apache Kafka (event streaming), SFTP
Selenium, JMeter, GitHub Actions, SonarQube, Artifactory
Average of 4 unplanned outages per month — each costing $50K+ in lost production time and manual workarounds.
70% of procurement and inventory tasks still required manual data entry and spreadsheet reconciliation.
Legacy system had no APIs — every data exchange with CRM, e-commerce, and suppliers done via CSV exports and manual uploads.
6 full-time staff dedicated to keeping the legacy system running — $900K annual maintenance for a system that couldn't scale.
8-week discovery phase — mapping every workflow across procurement, production, inventory, sales, and finance.
12 independent microservices — each deployable, scalable, and testable independently via event-driven architecture.
Custom ETL pipeline migrating 15 years of data with automated validation, reconciliation, and rollback capability.
Both systems ran in parallel for 90 days — automated data comparison ensuring 100% accuracy before legacy shutdown.
Real-time KPI dashboards built with QuickSight — production throughput, inventory turns, cash flow, and order fulfilment.
Department-specific training programmes, video guides, and on-site support during the 30-day post-launch stabilisation period.
Automated workflows reduced manual data entry by 85% and improved overall operational efficiency by 55%.
Legacy maintenance team reduced from 6 to 1, combined with cloud cost optimisation and vendor consolidation.
15 years of transactional data migrated with 100% accuracy — zero production disruption during the cutover.
Executive dashboards providing real-time KPIs across all departments — replacing 30+ manual Excel reports.
HubSpot CRM, Shopify B2B, and 8 supplier systems integrated via REST APIs — eliminating all CSV-based data exchange.
Platform architecture validated for 4-plant expansion — second plant onboarded in Year 2 with zero code changes.