Background and Challenges
An auto-parts manufacturer in East China with about 300 employees supplies stamped and injection-molded parts to car makers and tier-one suppliers. Finance and inventory ran on Yonyou ERP, while the shop floor was managed by a standalone MES. The two systems had no interface: every day a clerk exported picking and production reports from the MES and re-keyed them into the ERP, entering every figure twice.
Month-end close took five days as finance reconciled shop-floor consumption in a rush. Book stock and actual workshop stock drifted apart with no traceable source, and with no live view of work in progress or process costs, quoting and order acceptance ran on experience alone.
Our Approach
We delivered the Yonyou implementation in three layers: deployment and parameter configuration aligned inventory and costing rules with production management; custom development added bespoke documents and reports such as workshop consumption summaries and process cost statements; and an integration layer connected the MES to Yonyou, so equipment data, work-order progress and material issues write back to ERP automatically — no second entry on the shop floor.
Go-live followed a parallel-run plan: one month of dual operation to reconcile differences, then cutover once book and actual stock agreed, with separate hands-on training for the finance and workshop teams.
Results
- Month-end close shortened from 5 days to 1, with no more end-of-month catch-up (sample data, to be verified);
- Inventory book-to-actual match rate rose from about 92% to 98%, and stock discrepancies became traceable (sample data, to be verified);
- Picking, production and work-order data now flow in with zero manual re-entry (sample data, to be verified);
- Finance and production share one real-time dataset: work in progress and process costs are on hand at any moment.