QAD ERP Implementation - OPC Manufacturing

Client Profile

  • Company: OPC
  • Industry: Industrial Machinery Components
  • Size: 420 employees ~$85M annual revenue
  • Scope: Multi-site QAD ERP deployment across two manufacturing plants and one distribution center

Business Challenge

OPC's growth was hindered by disconnected legacy systems and reliance on spreadsheets. The absence of real-time inventory visibility, manual MRP processes, and inconsistent quality records across sites led to planning inaccuracies, production delays, excess inventory, and slow financial reporting. To sustain expansion and improve efficiency, OPC required a unified ERP platform tailored to manufacturing.

Project Objectives

  • Implement QAD Adaptive ERP to integrate Production, Inventory, Procurement, Customer Management, Quality, and Finance.
  • Automate MRP and enhance capacity planning through QAD's advanced supply chain capabilities.
  • Standardize processes across sites using QAD Process Maps and industry best practices.
  • Strengthen compliance and traceability with Quality Management and Lot/Serial Tracking.
  • Reduce operational and financial cycle times via end-to-end digital workflows.

Solution Approach

The ERP rollout followed a structured nine-month methodology covering Discovery, Solution Design, Configuration, Data Migration, Integrations, Testing, and Go-Live.

Key Highlights:

  • Configured QAD Manufacturing with work centers, routings, automated backflushing, and capacity calendars.
  • Deployed QAD Planning for MRP, forecasting, and supply planning.
  • Enhanced Quality Management with digital inspection plans and automated nonconformance workflows.
  • Implemented QAD Finance with standardized chart of accounts and automated cost roll-ups.
  • Integrated QAD with MES for machine data capture, supplier EDI, CRM order flow, and 3PL warehouse operations.
  • Migrated master data (items, BOMs, suppliers, customers) and open transactions using loaders and validation tools.
  • Delivered role-based training and established a multi-site super-user network to drive adoption.

Results & Outcomes

Operational Improvements

  • Inventory accuracy increased from 82% → 97%
  • MRP runtime reduced from 3 days → 3 hours
  • Production schedule adherence improved by 22%
  • Order fulfillment lead time reduced by 18%

Financial Impact

  • Month-end close shortened from 12 days → 5 days
  • Costing accuracy improved, enabling better pricing and quoting
  • Excess inventory reduced by $1.4M annually

Quality & Compliance

  • Achieved full digital lot/serial traceability
  • Improved audit performance with real-time electronic inspection results

Executive Summary

The QAD ERP implementation delivered OPC a unified, adaptive platform purpose-built for manufacturing. By replacing fragmented systems with integrated modules, OPC now enjoys real-time visibility, standardized operations, and enhanced supply chain performance. The company is positioned to scale efficiently, meet customer demands, and leverage QAD's automation and analytics capabilities for future growth.