Case Study 3: Implementation of Manufacturing Execution Software Integrated with BC/Dynamics NAV and 3rd Party Quality Module

Client: Leading Manufacturing Company Location: Ireland Solution: Manufacturing Execution System (MES) & Quality Control Digitisation Technology: Microsoft Dynamics NAV / Dynamics 365 Business Central, 3rd Party MES & Quality Module IntegrationIndustry: Manufacturing Project Scope: Multi-line Manufacturing Facility

Background

A prominent Irish manufacturing company faced critical challenges around quality control and production visibility. Key production data—including product run times, quality test results, and component traceability—was recorded manually on paper by operatives on the factory floor. This paper-based system resulted in delayed reporting, limited traceability, and frequent errors, making it difficult for managers to plan production accurately or enforce quality standards in real time.

Additionally, the lack of integration between production data and the company’s ERP system (Dynamics NAV / Business Central) prevented centralized monitoring, created bottlenecks in operations, and introduced compliance risks in regulated product lines.

To address these challenges, the company partnered with us to implement a modern Manufacturing Execution Software integrated with both Business Central and a third-party quality module, creating a digitally connected, data-driven production environment.

Objectives

• Digitally capture quality test results and production data in real-time• Eliminate manual, paper-based recording methods on the manufacturing floor• Enable live tracking of product run times to enhance production planning accuracy• Establish traceability between raw components and finished goods• Enforce a gated production process that prevents progression until all required data and tests are completed• Empower operatives with handheld devices for data entry and photo capture directly on the line• Ensure compliance with internal and external quality requirements• Integrate quality and production data with the core ERP (Business Central / NAV)

Our Approach

• Process Mapping & Gap Analysis: Conducted on-site workshops with production and quality teams to identify key data capture points and process bottlenecks.• MES & Quality Module Integration: Implemented a third-party MES solution configured to communicate with Business Central/NAV, allowing seamless synchronization of production events and quality data.• Digital Quality Capture: Designed intuitive forms for quality data input, including numeric tests, pass/fail checks, and photo evidence—all entered via handheld devices directly at the production line.• Traceability & Component Linking: Developed functionality to track individual product runs, linking finished goods to input components and recorded test data, enabling full traceability.• Gated Workflow Enforcement: Implemented mandatory checkpoints—products could not proceed to the next stage unless all required data was captured and verified.• ERP Integration: Connected production output, downtime, and quality metrics directly to Business Central/NAV, providing management with consolidated visibility.• Training & Go-Live Support: Delivered hands-on training for operatives and supervisors, supported phased rollout to minimize production disruption.

Results & Benefits

• 100% digital capture of production and quality test data.

• Real-time visibility of production run times and line performance.

• Enhanced manufacturing planning accuracy and efficiency.

• Full traceability between components and finished products.

• Reduction in quality errors and improved compliance

• Improved accountability and operator engagement through mobile data entry

• Ability to review photo documentation linked to specific production batches

• Seamless integration between ERP, MES, and quality systems

Conclusion

This project transformed the client’s manufacturing operations by replacing outdated, manual processes with a fully integrated MES and quality system connected to their ERP. The shift to real-time data capture enabled accurate planning, improved compliance, and end-to-end traceability—laying the foundation for scalable, smart manufacturing. With operatives equipped with modern tools and managers empowered with real-time data, the company is now positioned for continued growth and efficiency.

Case Study 4: Mobile Stocktake App Rolled Out for a Distribution Company in Ireland & the UK

Client: Leading Distribution CompanyLocation: Ireland and the United KingdomSolution: Mobile Stocktake ApplicationTechnology: Microsoft Dynamics 365 Business Central, Bespoke Mobile App, Microsoft Power BIIndustry: DistributionProject Scope: Multi-warehouse deployment (Ireland & UK)

Background

A leading distribution company operating warehouses across Ireland and the UK was facing serious inefficiencies in their stocktake process. Operatives were using paper and pen to record inventory counts, which were later manually reviewed and entered into the ERP by the Inventory Manager. This approach introduced errors, lacked real-time visibility, and caused delays in completing stock counts.

Without live data, recounts were only triggered after the entire process was complete—leading to delayed corrections, bottlenecks, and limited accountability among operatives. The manual process also meant warehouse operations were disrupted for extended periods during stocktake events.

To modernize the process, the company partnered with us to design and implement a bespoke mobile stocktake application fully integrated with Microsoft Dynamics 365 Business Central. The solution allowed operatives to record inventory directly on the floor while enabling real-time oversight and control through Power BI dashboards.

Objectives

• Eliminate paper-based stocktaking and manual ERP entry• Enable operatives to count stock directly via mobile devices on the warehouse floor• Provide live visibility of stocktake progress and values to the Inventory Manager• Allow for instant identification of discrepancies and trigger live recounts• Improve stocktake speed and data accuracy• Enable one-click posting of verified stocktakes into Business Central• Create accountability by tracking operative performance through BI analytics• Reduce disruption to warehouse operations during stocktaking

Our Approach

• Requirements Gathering & Process Mapping: Conducted workshops with inventory teams to map the existing stocktake process and identify pain points.• Custom Mobile App Development: Built a lightweight, user-friendly mobile application tailored to the client’s warehouse layout and stocktake procedures.• Real-Time ERP Integration: Integrated the mobile app with Business Central to sync count data live as entries were recorded by operatives.• Power BI Dashboarding: Developed a live Power BI report for the Inventory Manager showing stocktake progress by bin, current value impact (write-ups/downs), and operative-specific performance metrics.• Recount Triggers: Enabled the Inventory Manager to flag discrepancies for immediate recount, ensuring data was reviewed and corrected before posting.• One-Click Posting: Designed a controlled final review screen that allowed the manager to post the complete stocktake into Business Central without any re-entry.• Training & Support: Provided tailored training sessions for operatives and supervisors, ensuring a smooth transition from manual to digital.

Results & Benefits

• 50% reduction in stocktake duration

• 100% elimination of manual stocktake data entry

• Real-time stocktake visibility and discrepancy tracking

• Increased accountability among operatives via BI-based performance metrics

• Immediate recount capabilities during the count phase

• Improved stock accuracy and reduced write-off variances

• Seamless ERP posting with no administrative overhead

Conclusion

By deploying a bespoke mobile stocktake application integrated with Business Central, the client replaced a time-consuming, error-prone manual process with a fast, accurate, and transparent digital workflow. The solution not only halved the time required to complete stocktakes but also introduced real-time oversight and data-driven accountability—creating a more efficient and reliable inventory management process across all warehouse locations.