Legacy ERP System Optimization for Manufacturing Industry

Stabilizing Complex Manufacturing Operations While Preparing for What’s Next.

In complex manufacturing environments, a partially stable ERP can still create daily operational risks, primarily when it supports production planning, inventory control, dispatch, and financial reporting. A leading electrical components manufacturer in India relied on a legacy ERP system that had gradually become a bottleneck. Over time, technical debt accumulated, data mismatches increased, and report inconsistencies became frequent. Manual intervention slowed down operations and reduced confidence in critical numbers.

The manufacturer partnered with Rishabh Software to stabilize the legacy ERP system for discrete operational needs while retaining the existing platform. The goal was to restore trust in inventory and financial output while reducing operational friction without disrupting production.

Capability

Application Development and Maintenance Services

Industry

Electrical Components Manufacturing

Country

India

Key Initiatives

To support the client, we launched a targeted ERP stabilization program centered on strong governance and execution discipline to improve stakeholder clarity. The engagement combined our digital manufacturing expertise with application modernization services to stabilize discrete manufacturing operations and prepare the legacy ERP for long-term optimization without replatforming.

No-replatforming stabilization strategy

We kept the ERP and the underlying tech stack unchanged and applied only surgical fixes to stabilize production, inventory, and finance workflows. This ensured Legacy ERP system optimization without forcing a platform change.

Root-cause driven triage for a legacy system

Established a trace-and-fix approach to navigate scattered logic across stored procedures, views, and reports, helping the team identify root causes faster instead of applying surface-level patches.

Phased delivery with business continuity priority

We executed the work in clear phases and protected day-to-day operations by prioritizing production and finance continuity first, then moving to stabilization, reporting discipline, and prevention.

Change communication and validation discipline

We set a simple rhythm for review and validation so fixes could be tested, approved, and released with fewer back-and-forth cycles during UAT.

Challenges

Fragmented Legacy ERP Logic: Business rules were scattered across multiple stored procedures, views, and reports, making it difficult to trace the root causes of issues.

Stock Mismatches and Data Drift: WIP and MTC balances sometimes diverged due to inconsistent calculation dimensions, leading to manual reconciliation during planning.

Inter-Store Transfer Failures: Raw-material transfer logic had edge cases, causing silent failures that disrupted production and created rework.

Reporting Friction: Debtor reports were outdated, suffered from legacy naming conventions, and had inconsistent parameters, which caused export failures and confusion.

Slow UAT Cycles: PDFs included irrelevant historical data that slowed approvals and led to rework.

Solutions

The team worked within the existing ERP to reduce risk and restore stability fast. Instead of large changes, we prioritized production and finance continuity, stabilized core calculations and workflows, improved reporting reliability, and added lightweight controls to prevent repeat incidents. The technology stack remained unchanged to minimize operational disruption.

Rapid hotfixes for production and finance continuity

Delivered immediate fixes to unblock business-critical operations by resolving high-priority issues in core workflows.

Platform stabilization through aligned calculations and refactoring

Aligned calculations across modules and refactored high-impact stored procedures and views to remove inconsistencies and improve reliability.

Reporting hygiene and export reliability

Standardized report names and parameters, removed ambiguity from legacy variants, and fixed export failures to make reporting consistent and dependable.

Guardrails and Traceability

Documented every change, including objects touched and versions, added basic test checks, and defined simple SOPs for data corrections to reduce repeat incidents and support audits.