ERP consolidation for a multi-plant manufacturer
Anonymized work consolidating three plant-level systems and a finance spreadsheet stack onto a single deployment of Vestval One.
Tools / product used · Vestval One
Challenge
Three plants ran three different inventory and production systems. Finance reconciled monthly in spreadsheets. Leadership had no live operating picture and capital planning was reactive.
Objectives
- Single source of truth across three plants
- Materially shorter monthly close cycle
- Live operating picture for leadership
- Retire three legacy systems on schedule without stopping production
Approach
We audited each plant's actual process, designed a unified data model that respected real plant differences, and staged a rollout that retired one legacy system at a time without breaking production.
Solution
Vestval One configured for multi-entity reporting, plant-level workflows, and integrations with existing MES and HRMS. Custom dashboards for plant managers and a unified P&L view for the CFO.
Implementation approach
- 1
Plant-by-plant process audit
Two weeks per plant — actual processes, not documented ones — feeding a unified data model that respected real differences.
- 2
MES integration before replacement
Existing MES systems kept and integrated at the data layer; no shop-floor disruption.
- 3
Sequenced cutover
One plant cut over fully, hardened for four weeks, then sequenced across the other two.
- 4
Finance close transformation
Month-end close redesigned around live data, with the legacy spreadsheet stack retired in the second close cycle.
Technologies used
- Vestval One
- Multi-entity finance module
- MES data integration
- Plant manager dashboards
- Vestval Flow approval workflows
Outcomes
- Single source of truth across three plants
- Monthly close cycle materially shorter (qualitative)
- Leadership operating picture moved from monthly to near-real-time
- Three legacy systems retired on schedule
Lessons learned
- Respect plant differences in workflow, unify them in data — not the other way around.
- Never replace MES on day one. Integrate first.
- Sequenced rollouts always beat simultaneous ones in multi-plant programs.
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