Case study • Manufacturing • Enterprise Analytics Modernization

80% Reduction in Reporting Effort Through Unified Manufacturing Analytics

We partnered with client, a leading national manufacturer operating nearly 90 production facilities, to modernize its analytics ecosystem during a large-scale ERP transformation. By unifying data across legacy and modern ERP systems, automating reporting workflows, and implementing a scalable Microsoft Fabric architecture, we delivered executive-ready visibility into profitability, inventory health, and operational performance.

Success Highlights

  • 80% reduction in manual reporting effort
  • 90-plant executive visibility through unified analytics
  • 40% faster data processing compared to legacy ETL tooling

Key Details

  • Industry: Manufacturing
  • Geography: United States
  • Platform: Microsoft Fabric, Oracle NetSuite, Microsoft Navision, Power BI

Business Challenge

As the client transitioned from Navision to Oracle NetSuite, reporting became fragmented across legacy systems, modern ERP environments, and manually maintained Excel reports.

  • Fragmented ERP Reporting: Historical and current data resided across multiple systems, eliminating a single source of truth for executive reporting.
  • Legacy ETL Scalability Constraints: Jet Data Manager’s desktop-driven architecture struggled to support growing data volumes and onboarding of new sources
  • Manual Plant Reporting: Data consolidation from approximately 90 manufacturing plants relied heavily on spreadsheets and manual reconciliation.
  • Complex Profitability Calculations: Accurate margin reporting required integrating labor, materials, logistics, purchasing, and services data across multiple product configurations.

Our Solution Approach

We implemented a data integration and visualization strategy to unify data sources, improve data quality, and enable real-time insights.

1 · Assess

Evaluate Reporting Fragmentation & Data Complexity

Evaluated ERP migration impacts, reporting dependencies, profitability calculations, and existing ETL bottlenecks across manufacturing and finance functions.

2 · Unify

Build Enterprise Lakehouse Architecture

Designed a Medallion (Bronze-Silver-Gold) architecture within Microsoft Fabric to centralize data from Navision, NetSuite, and plant-level reporting systems.

3 · Modernize

Standardize Data Pipelines & Processing

Implemented full and incremental ingestion pipelines, automated data quality controls, and standardized business logic to eliminate manual reporting dependencies.

4 · Enable

Deliver Executive Analytics & Governance

Built centralized semantic models, Power BI dashboards, and governance controls to support profitability analysis, operational visibility, and future analytics expansion.

Technical Highlights

  • Microsoft Fabric Lakehouse architecture using Bronze-Silver-Gold data layers
  • Hybrid ERP integration across Microsoft Navision and Oracle NetSuite environments
  • PySpark-based transformation framework for cleansing, deduplication, and business-rule processing
  • Incremental and full-load ingestion pipelines aligned to operational reporting cadences
  • Power BI semantic models with centralized KPI definitions and DAX calculations
  • Git-integrated version control for pipelines, notebooks, and reporting assets Azure Data Lake Storage Gen2 supporting scalable enterprise data storage
  • u003cstrongu003eGovernance controls including RBAC,u003cstrongu003e lineage tracking, dataset certification, and Git deployments
// Python 
// Python - Multi-Cloud Deployment Trigger Logic
def deploy_service(commit):
if run_ci_checks(commit):
build_docker_image(commit)
deploy_to_cloud(target="AWS_ECS")
update_monitoring_dashboard()
else:
notify_team("Deployment Failed")

Business Outcomes

Established a unified analytics foundation that improved reporting efficiency, profitability visibility, and enterprise-wide decision-making.

80%
Reduction in Reporting Effort:

Automated reporting workflows significantly reduced manual data consolidation performed by finance and plant operations teams.

200+
Hours Automated Monthly:

Eliminated repetitive Excel-based reporting activities through centralized dashboards and automated data pipelines.

40%
Faster Data Processing

Modernized cloud-native analytics pipelines delivered significantly faster processing than legacy ETL tooling.

  • Executive visibility into performance across 90 manufacturing plants
  • Support for 90,000+ tables without performance degradation
  • 99.9% data accuracy through automated validation and reconciliation
  • Zero data loss during ERP migration activities
  • Complete auditability through Bronze-layer data preservation
  • AI/ML-ready analytics foundation for future forecasting initiatives
Modernizing Analytics During an ERP Transformation?
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