Multi-division manufacturing group · India
ERP integration and operations visibility program
Representative product engineering programs delivered by Zestlan. Client names withheld where confidentiality agreements require. Metrics reflect documented outcomes from production deployments.
Context
Manufacturing divisions ran independent ERP instances and warehouse tools. Executive reporting required manual consolidation each week.
Finance spent disproportionate time reconciling inventory movements against production records.
Challenge
Production, inventory, and finance teams worked from separate systems with delayed reporting and manual reconciliations.
Solution
API-led integration between ERP, warehouse, and executive dashboards with governed master data and automated workflow alerts.
Constraints
- No big-bang ERP replacement — integration had to respect existing division autonomy
- Master data governance for parts, locations, and cost centers across six systems
- Near-real-time alerts for inventory exceptions without overloading source systems
Architecture
Integration hub with canonical master data, event notifications, and executive analytics — not another monolithic ERP.
Integration hub
API and message connectors with retry and dead-letter handling.
Master data service
Governed golden records with change approval workflow.
Exception alerting
Notifications when inventory, production, or finance signals diverge.
Executive analytics layer
Daily refreshed dashboards replacing weekly manual consolidation.
Technology stack
Delivery approach
Mapped data flows and reconciliation pain points across six systems.
Established golden records before connector build-out.
Finance reconciliation integrations first.
Operational visibility and exception routing to division owners.
Measured outcomes
- 35% reduction in manual reconciliation effort across finance and operations
- Daily operational reporting available instead of weekly batch exports
- 6 core systems connected through a documented integration layer
Engineering lessons
- Master data governance was the bottleneck — connectors without golden records recreate chaos at API speed.
- Daily reporting beat real-time everywhere; executives needed consistency more than sub-second latency.
- Dead-letter queues and integration observability prevented silent data drift across six systems.
Discuss your product program
Every engagement is scoped to your business model, users, and constraints — detailed reference material available under NDA for qualified evaluations.