An ERP replacement succeeds when the factory can complete critical work and trust the starting data after cutover. The project plan should protect that outcome from the first workshop.
1. Inventory the current operating system
List modules, custom fields, reports, integrations, scheduled jobs, spreadsheets, approval rules, users, and external handoffs. Mark each as retain, replace, redesign, archive, or retire.
2. Rank business-critical workflows
Start with the flows that create revenue, move stock, control quality, meet compliance, or release payments. Define the minimum parity result for each.
3. Decide what history moves
Prepare clean masters, opening stock, open orders, active WIP, outstanding documents, and audit or traceability history required in daily work. Archive the remainder in a searchable, read-only form.
4. Build and test the target workflow
Configure roles, approvals, stages, and reports. Test normal work plus partial quantities, alternate UOMs, rejection, rework, returns, and failures in retained-system integrations.
5. Rehearse cutover
Run the final exports, imports, reconciliations, and sign-offs before the real cutover. Name the decision-maker, final transaction time, communication plan, and response for any failed control total.
6. Stabilise daily operations
Track incomplete transactions, user adoption, stock variances, interface failures, and reporting questions every day until owners trust the new flow.
FactoStack's Factory Go-Live can establish the first replacement workflow. Prepare with the implementation checklist, timeline, Excel migration guide, cost guide, and pricing.
Factory Go-Live covers the agreed first workflow; custom modules, retained-system integrations, and historical reconstruction receive their own scope and quote.
Frequently Asked Questions
Written by
Sudharsan GS
Building FactoStack with Indian MSME manufacturers across inventory, production, dispatch, GST, and Tally workflows.
