Epicor ERP Implementation for a Metal Fabrication Manufacturing Company  

Industry: Metal Fabrication Manufacturing
ERP Solution: Epicor ERP
Implementation Partner: AGN IT Services
Location: UAE

Business Background  

The client is a mid-sized metal fabrication company supplying custom metal components to construction and industrial projects across the UAE. Their operations included cutting, welding, machining, and finishing, with multiple production lines running simultaneously. As the business grew, managing production schedules and material planning became increasingly complex.

Despite having skilled workers and modern machinery, the company faced delays, wastage, and poor coordination between departments. Management realized that without a proper manufacturing ERP system, future growth would be difficult.

Challenges Faced  

Before Epicor ERP implementation, the company relied heavily on manual planning and disconnected software tools. The major challenges included:

• Inaccurate production planning

• Frequent raw material shortages

• Delayed job orders and missed deadlines

• No real-time visibility into work-in-progress

• Manual tracking of Bill of Materials (BOM)

• Difficulty in forecasting material requirements

Production managers were constantly firefighting. Even small changes in customer orders caused confusion on the shop floor. This led to overtime costs, unhappy customers, and stressed teams.

Solution Provided by AGN IT Services  

AGN IT Services conducted a detailed business analysis to understand the client’s production flow, machine usage, and material consumption. Based on this assessment, Epicor ERP was selected as the best-fit ERP solution for their manufacturing needs.

Key Epicor ERP modules implemented included:

• Production Management

• Material Requirements Planning (MRP)

• Bill of Materials (BOM)

• Inventory Management

• Shop Floor Control

AGN IT Services customized Epicor ERP to match the client’s real production workflow instead of forcing them into generic processes. Production schedules were automated, and BOMs were accurately defined for each product.

Implementation Process  

The implementation was carried out in phases to avoid disruption:

1. Data migration from spreadsheets to Epicor ERP

2. BOM structuring and validation

3. Production workflow configuration

4. User training for production and planning teams

5. Go-live support and optimization

AGN IT Services ensured the production team was fully trained and confident using the system.

Results Achieved  

After implementing Epicor ERP, the company saw clear improvements within the first few months:

• Production planning accuracy improved by over 35%

• Raw material shortages reduced significantly

• On-time job completion increased

• Better coordination between planning and production teams

• Real-time tracking of work-in-progress

Management gained complete visibility into production status, allowing faster and smarter decision-making.

Business Impact  

Epicor ERP helped the company shift from reactive planning to proactive manufacturing control. Production delays reduced, customer satisfaction improved, and internal stress levels dropped.

Conclusion  

By implementing Epicor ERP with AGN IT Services, the metal fabrication company transformed its production operations. The ERP system became the backbone of their manufacturing process, supporting efficiency, accuracy, and scalable growth.