Author: Andrew Jolliffe in: Management
News
Operations
Your ERP system is supposed to be the backbone of your operation. An ERP system that no longer is the right fit, is a hidden drain on your productivity and profit. For small and mid-sized manufacturers, this creates more problems than it solves.
If you are in metal fabrication, machining, or surface coating and you’re dealing with manual workarounds, or frequent downtimes, ignoring these warning signs will cost you thousands every month that goes by.
Here are 5 red flags to watch out for, and what to do about them.
No doubt, Excel is one of the most powerful software products ever built. Spreadsheets are useful for quick fixes and tasks, but if your business still relies on them for core tasks like scheduling, inventory tracking, or reporting, its a major red flag. Spreadsheets weren’t built for the complexity of a manufacturing shop floor.
Every time your team exports data into Excel, you’re introducing delays and mistakes. A missed formula or outdated entry throws off your production plan, creates bottlenecks, and causes costly downtime. Most importantly, spreadsheets don’t give you real-time visibility. By the time you’re reviewing the numbers, they’re already outdated.
Manual spreadsheets mean:
An ERP should be your single source of truth. If your ERP forces you to keep falling back on spreadsheets, it’s not just inconvenient, its a sign that your system is holding your business back.
Data should be the lifeblood of your operations. If your ERP can’t deliver live updates on machine performance, inventory levels, or work orders, you’re essentially making decisions in the dark. Without trusted, real-time data, you’re reacting to problems instead of preventing them.
Legacy systems often struggle to connect to modern machines, IoT devices, or shop floor software. That disconnect leaves your guessing about production bottlenecks, equipment breakdowns, or material shortages. The results? You’re always one step behind, responding too late to issues that should have been flagged earlier.
When your team doesn’t trust the data coming out of your ERP, they’ll revert to “workarounds”, double-checking numbers, creating parallel reports, and wasting valuable time. Bad data isn’t just inconvenient, it’s dangerous. It increases costs, slows down decisions, and puts your reputation with customers at risk.
Few things are more expensive to a manufacturer than unplanned downtime. Every minute, or hour a machine is down, you’re losing productivity, delaying orders, and burning money. If your ERP isn’t helping you minimize downtime, its failing at one of it’s most critical roles.
A manufacturing ERP should give you proactive insights warning you of maintenance needs before machines fail, automatically reordering parts and raw materials, and keeping schedules aligned with both machine and labour availability. Without these safeguards, you’re stuck reacting to breakdowns instead of preventing them.
If you keep getting downtime surprises it’s not “bad luck”- its a clear sign that your system is outdated. If you are getting surprised by equipment failures, late parts, or scheduling conflicts, your ERP isn’t doing the job. A manufacturing ERP should:
Over time, the hidden cost of these disruptions can ruin your reputation, and leave you uncompetitive.
We say it time and time again your ERP is the backbone of your organization and should keep purchasing, production, and shipping in sync. If you’re constantly battling late orders, material shortages, or overstocking, your ERP is part of the problem.
Legacy systems struggle to coordinate schedules and inventory in real time, leading to scheduling conflicts, production delays, and costly firefighting to keep operations moving. Too little inventory, and your production stops cold. To much inventory, and your cash flow gets tied up in unused stock. Neither scenario is sustainable.
When scheduling and inventory are “always out of sync” your operations are stuck in a cycle of inefficiency. It frustrates employees, erodes customer trust, and makes it nearly impossible to scale. A manufacturing ERP solution should bring order and visibility to an otherwise chaotic situation.
If you are constantly battling scheduling and inventory headaches, it’s a clear sign that your ERP needs an upgrade.
As your business evolves, so should your ERP solution. If you’re stuck with expensive support contracts, slow updates, or clunky user interfaces that your team dreads using, you’re slowing them down.
Technology should work for you, not against you. An ERP solution like OnRamp provides regular updates that keep your business compliant and competitive, along with responsive support that ensures issues never become roadblocks. When your system no longer adapts to your needs, it slows growth, creates inefficiencies, and increases risk. For customers, this means wasted time, higher costs, and missed opportunities. If your current system makes you feel trapped instead of empowered, it is a strong sign it is time to move on.
Your ERP should be reducing headaches, not creating them. If you experience the challenges of any ineffective ERP in your operations, it is time to look at a, fully integrated manufacturing ERP that was built specifically for you and fits the realities of your business.
Upgrading your ERP means fewer manual tasks, better data, less downtime, and a healthier bottom line.
Are you ready to see what a manufacturing ERP can do for your company? Talk to us today and discover how we are helping manufacturers stay ahead.
Check out our related blog on how How to Choose the Right ERP System for Small and Mid-Sized Manufacturers
For more information about how OnRamp ERP software can add value to your business fill in the contact form below. A member of our support team will contact you within 1 business day to discuss any questions you have.
Start the collaboration with us while figuring out the best solution based on your needs.
Our efforts began as an internal project of Mancor Industries when we identified the need for a more cohesive ERP system to manage the complexity of multiple plants, multiple products, multiple customers and multiple functions.
Read MoreHas your business outgrown a patchwork of disconnected systems? This checklist helps you assess readiness, identify gaps, and prepare for a smooth transition.
