ManufacturingMulti-plant industrial manufacturer

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…

Solution

Vestval One configured for multi-entity reporting, plant-level workflows, and integrations with existing MES and HRMS. Custom dashboards…

Architecture

We audited each plant's actual process, designed a unified data model that respected real plant differences, and staged a rollout that…

Timeline

4-phase implementation · Vestval One

Impact

Single source of truth across three plants

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.