Aurora Operations: Multi-Plant Manufacturing & Supply Chain ERP
Enterprise resource planning and supply chain platform coordinating raw materials procurement, bill of materials (BOM), multi-plant inventory, and export compliance for 3 industrial factories.
Project Overview
Aurora Manufacturing operates 3 industrial fabrication and apparel production units. Managing over 4,500 active raw material SKUs through spreadsheets and disconnected accounting tools resulted in production line stoppages due to unrecorded material stockouts and inaccurate product cost estimates.
Multi-Factory Disconnect, Fabric Waste & Delayed Export Shipments
The leadership required a single authoritative system linking raw material stores, production tracking, commercial export documentation, and real-time cost accounting.
Unified Manufacturing Execution & Inventory Allocation Engine
Custom web-based ERP engineered with Next.js, TypeScript, PostgreSQL, and Prisma with micro-services for inventory ledger calculations and role-based approval hierarchies.
System Architecture & Interface Previews
Supply Chain & Factory Floor Command Center
Interactive Bill of Materials (BOM) Configurator
Warehouse Inventory Barcode Tracking
Execution Sprints & Methodology
Plant Process Mapping
Mapped raw material entry, cutting, assembly, finishing, and packaging workflows across all 3 plants.
Schema Normalization
Designed robust relational schemas handling complex multi-unit conversions (meters, kilograms, yards, rolls).
Module Development
Engineered procurement, inventory, floor tracking, and finance modules in continuous weekly sprints.
Data Cleanse & Migration
Migrated 8 years of historical vendor pricing and SKU catalogs into PostgreSQL.
Floor Operator Training
Conducted bilingual hands-on training sessions with warehouse managers and machine supervisors.
Verified Project Outcomes
Purchase order approval and vendor assignment streamlined from 12 days to under 4.5 days.
Automated minimum-order formulas prevented over-purchasing of seasonal raw materials.
Zero shipment delays due to missing paperwork or unfulfilled material inputs.
"SmartEdge delivered an ERP that our factory supervisors actually enjoy using. We now know our exact manufacturing margins down to the last penny on every single export container."
Technologies Deployed in This Solution
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