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Legacy ERP Modernisation

Moving a fifteen-year-old ERP to a supported platform without stopping the business.

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Case Study · Manufacturing

Legacy ERP Modernisation

The challenge

A regional manufacturer was running a 15-year-old ERP on aging servers. The system crashed during month-end close, required manual re-keying between sales, production and accounting, and the original vendor no longer supported it.

An ageing shop-floor terminal beside production machinery

How we solved it

  • Documented every integration and report before touching production.
  • Ran a parallel pilot so staff could learn the new system with real data.
  • Cut over on a scheduled weekend with a rollback plan agreed in writing.
Project solution in a modern office setting

The outcome

Manual re-keying between sales, production and accounting largely disappeared, month-end close became faster and more predictable, and the business now has a supported platform its staff trust.

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What made it harder — and how we handled it

The biggest hidden risk was not the software itself but the undocumented connections between systems. Before any code changed, we mapped every report, import and export so that nothing silently broke on go-live.

We ran the new system in parallel for a month so staff could compare results with the old one. That parallel period felt slow, but it is what gave the client confidence to switch over without a standstill.