ARIONERP CASE STUDY: ELECTRONICS MANUFACTURING

How an Electronics Manufacturer Reduced Assembly Waste by 25% and Boosted Throughput with ArionERP

A detailed look at integrating lean manufacturing principles and Product Lifecycle Management (PLM) to overcome supply chain disruption and scale production.

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Lean Assembly and PLM Optimization An abstract illustration showing a streamlined production line with data flowing through it, representing efficiency and connectivity.
Real-Time Production Analytics Shop floor data integrated with inventory and PLM.
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The Challenge: Scaling Production Amidst Complexity

Volt-Tech Components, a mid-sized manufacturer of high-performance circuit boards for the automotive and aerospace industries, was at a critical juncture. Rapid growth and increasing product complexity were straining their legacy systems—a patchwork of spreadsheets, standalone inventory software, and manual processes. This disconnected environment led to significant operational challenges that threatened their ability to scale and maintain their reputation for quality.

Key Challenges Faced:

  • High Scrap & Rework Rates: Inaccurate Bill of Materials (BOMs) and poor version control meant assembly teams often used outdated schematics, leading to a scrap rate of over 8% and costly rework.
  • Lack of Supply Chain Visibility: With no real-time view of component inventory, unexpected stockouts frequently halted production lines, causing costly delays and jeopardizing delivery commitments.
  • Inefficient Product Lifecycle Management: The engineering change order (ECO) process was manual and slow, taking days to communicate across departments. This delayed the implementation of crucial design improvements and new product introductions.
  • No Real-Time Data for Decision-Making: Management lacked access to live shop floor data, making it impossible to identify production bottlenecks, measure OEE (Overall Equipment Effectiveness) accurately, or make informed strategic decisions.

The Solution: An Integrated Lean Manufacturing & PLM Platform

ArionERP was selected to replace Volt-Tech's fragmented systems with a single, unified platform. The goal was to implement a solution that not only managed core business processes but also deeply integrated lean manufacturing principles with robust Product Lifecycle Management (PLM) capabilities. The implementation focused on creating a seamless flow of information from design and engineering through to procurement, production, and quality assurance.

Our Strategic Implementation:

  1. Unified Data Foundation: We migrated all product data, including multi-level BOMs, CAD files, and compliance documents, into ArionERP's central PLM module. This created a single source of truth, ensuring everyone from engineering to the shop floor worked from the latest revisions.
  2. AI-Powered Inventory & MRP: ArionERP's AI-driven Material Requirements Planning (MRP) system was configured to analyze historical consumption, current demand, and supplier lead times. This provided predictive insights, automated purchase orders, and maintained optimal component stock levels, virtually eliminating line-stopping shortages.
  3. Digital Shop Floor Control: We deployed tablets on the assembly line running ArionERP's Manufacturing Execution System (MES) interface. This provided operators with digital work instructions, real-time access to the correct BOMs and schematics, and a simple interface for tracking production progress and reporting quality issues.
  4. Automated Quality & Compliance Workflows: The Quality Management module was configured to automate in-process quality checks at critical assembly stages. Any deviations triggered instant alerts to quality engineers, allowing for immediate corrective action and ensuring full traceability for their aerospace and automotive clients.

Key ArionERP Modules in This Solution

This transformation was powered by a tightly integrated suite of ArionERP modules, designed to create a seamless data flow across the entire manufacturing lifecycle.

Manufacturing (MRP & MES)

Provided the core engine for production planning, scheduling, and shop floor execution. Enabled real-time tracking of work orders and resource utilization.

Product Lifecycle Management (PLM)

Centralized all engineering data, managed BOMs, and automated the ECO process, ensuring data integrity from design to production.

Inventory Management

Delivered a real-time, 360-degree view of all components, sub-assemblies, and finished goods, with AI-driven forecasting to prevent stockouts.

Quality Management

Automated quality control checkpoints, managed non-conformance reporting, and provided complete traceability for compliance and audits.

Supply Chain Management

Optimized procurement processes, managed supplier performance, and provided visibility into the entire supply chain to mitigate risks.

Business Intelligence (BI)

Offered customizable dashboards that visualized key performance indicators like OEE, scrap rates, and on-time delivery in real-time.

Avatar for Michael Harper
"ArionERP didn't just sell us software; they gave us control over our production. For the first time, we have a single source of truth from engineering to the assembly line. The reduction in waste and the increase in throughput paid for the system in under 18 months. It's been a complete game-changer for our ability to scale."
Michael Harper, VP of Operations Volt-Tech Components, Automotive Electronics

Why ArionERP for Electronics Manufacturing?

Our platform is engineered to address the specific, high-stakes challenges of the electronics industry. We go beyond generic ERP features to deliver solutions that drive tangible results on the factory floor.

Deep Domain Expertise

We understand the nuances of electronics assembly, from complex BOMs and revision control to traceability and compliance requirements.

AI-Powered Forecasting

Our AI engine analyzes demand patterns and supply chain variables to predict component needs, preventing costly production stoppages.

Integrated PLM & MES

A seamless connection between engineering (PLM) and the shop floor (MES) eliminates data silos and ensures production always uses the right designs.

Real-Time Shop Floor Control

Empower your team with digital work instructions and instant data capture for unparalleled visibility and control over production processes.

Built-in Compliance & Traceability

Effortlessly track every component from receiving to shipping, simplifying audits and meeting strict industry standards (e.g., ISO, AS9100).

Agile & Scalable Platform

ArionERP grows with you. Our flexible architecture allows you to adapt processes and add functionality as your business evolves.

More Success Stories in Manufacturing

See how we've helped other complex manufacturers achieve operational excellence.

Case Study: Achieving FDA Compliance & Full Traceability for a Medical Device Maker

Client: Precision Medical Instruments, a manufacturer of surgical devices.

Challenge: The client struggled with manual, paper-based device history records (DHRs) and lot tracking. This made FDA audits stressful and time-consuming, and a product recall would have been a catastrophic, untraceable event.

Solution: ArionERP's Quality Management and Manufacturing modules were implemented to create an electronic DHR (eDHR) system. Every component, process, and quality check was automatically recorded against the device's serial number.

  • Enforced serialized tracking from raw material to finished product.
  • Automated generation of compliance documentation for each batch.
  • Integrated CAPA (Corrective and Preventive Action) workflows.
  • Provided a secure, audit-ready digital trail for regulators.
100%
Digital Traceability
75%
Reduction in Audit Prep Time
50%
Faster Non-Conformance Resolution

Case Study: Just-in-Time (JIT) Inventory for a Tier 1 Automotive Supplier

Client: Auto-Systems Inc., a supplier of electronic control units (ECUs) to major auto manufacturers.

Challenge: The client faced immense pressure to maintain low inventory levels while guaranteeing 100% on-time delivery to OEM assembly lines. Their inaccurate demand forecasting led to either costly excess inventory or expensive expedited freight to avoid shutting down their customer's production.

Solution: ArionERP's Supply Chain and EDI (Electronic Data Interchange) modules were deployed to create a true JIT system. We established a direct EDI link with their customers to receive real-time demand signals.

  • Automated intake of customer production schedules via EDI.
  • AI-powered demand forecasting to anticipate fluctuations.
  • Automated supplier releases based on JIT principles.
  • Real-time alerts for any potential disruption in the supply chain.
40%
Reduction in Inventory Holding Costs
99.9%
On-Time In-Full (OTIF) Delivery Rate
80%
Decrease in Expedited Freight Costs

Frequently Asked Questions

Answers to common questions about implementing ArionERP for electronics manufacturing.

While every project is unique, a phased implementation for a mid-sized electronics manufacturer typically ranges from 4 to 8 months. Our QuickStart packages can get core financials and inventory live in as little as 12 weeks, with more complex modules like PLM and MES layered in afterward to minimize disruption.

Absolutely. Our PLM module is designed with open APIs and pre-built connectors for major CAD platforms like Autodesk, SolidWorks, and CATIA. This allows for seamless synchronization of engineering data, BOMs, and design files directly into the ERP, eliminating manual data entry and errors.

We offer both. You can choose our secure, multi-tenant ArionERP Cloud (SaaS) option for zero infrastructure overhead, or deploy ArionERP On-Premises on your own servers for maximum control. The functionality is identical across both deployment models, giving you the flexibility to choose what's right for your business.

ArionERP excels at managing deep, multi-level BOMs with thousands of components. Our system supports phantom assemblies, configurable products, and full revision control. You can easily manage variants, track changes through the ECO process, and perform detailed cost roll-ups, ensuring accuracy from engineering to finance.

Ready to Eliminate Waste and Scale Production?

See how ArionERP can provide the visibility and control your electronics manufacturing business needs to thrive. Schedule a personalized demo with one of our industry experts today.

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