When off-the-shelf ERP stops being enough

The decision comes down to configuration limits, total cost, and how standard your operation is. If your BOM structure, costing model, or production routing doesn't fit the standard data model, you spend months in a configuration project that still ends with a system requiring workarounds. For mid-size manufacturers with $5M to $100M in revenue, the licensing and implementation cost of a tier-one ERP often exceeds the cost of a custom build owned outright.

We use a phased approach: the first phase covering production order management, inventory, and basic procurement typically delivers as a working module in 16 to 22 weeks. Finance integration, supplier portal, and multi-site reporting follow in later phases. Full replacement including historical data migration runs 24 to 36 weeks depending on data complexity and external integrations.

Yes, and this is often the right starting point. Many manufacturers need one part of their ERP replaced or extended, a production management module bolted onto their existing finance system, or a supplier portal that connects to an ERP they're otherwise happy with. Integration patterns depend on what the existing system exposes.

Manufacturing ERP is a large, multi-module build, so we scope it in phases rather than as one upfront price. A first production module for a single site, covering production orders and inventory, typically starts around $40,000 to $70,000 depending on scope and integrations. The full custom ERP covering production, procurement, finance, and multi-site reporting grows to roughly $140,000 to $240,000 across phased releases. The cost is fixed and agreed before each phase, so you fund proven value rather than an open-ended estimate.