Optimizing IT Systems for Greater Efficiency and Safety

At Emmett & Company, we understand that modernizing IT infrastructure in manufacturing goes well beyond software upgrades—it demands a holistic transformation that aligns systems, processes, and people. When this mid-sized manufacturing firm reached out to us, they were dealing with outdated on-prem systems, inconsistent data across departments, and growing concerns around production delays and system downtime.

Our engagement began with a deep-dive infrastructure and workflow assessment. We uncovered a fragmented environment: legacy ERP systems that lacked integration, outdated databases managed locally by different departments, and equipment still relying on manual input and paper-based reporting. These inefficiencies led to delayed production timelines, data silos, and an inability to generate timely insights across facilities.

We implemented a phased modernization roadmap, starting with the migration of critical applications to a cloud-based infrastructure with real-time data syncing across production, procurement, and inventory systems. We introduced secure, role-based access controls, ensuring data integrity while reducing internal IT bottlenecks. Our team built live dashboards for operations managers to track OEE (Overall Equipment Effectiveness), flag anomalies on the floor, and reduce reaction times to equipment malfunctions.

We also designed automated reporting workflows that eliminated redundant data entry and significantly reduced clerical errors in scheduling and maintenance logs. These improvements not only freed up hours of administrative time but also empowered team leads with data-backed decision-making tools.

To ensure a smooth transition, we conducted targeted training workshops with production supervisors, IT staff, and admin personnel. Our change enablement team created visual SOPs, onboarding guides, and department-specific playbooks to encourage adoption and reduce disruption during rollout.

By the end of the engagement, the organization had evolved from a patchwork of disconnected systems into a unified, agile operation with measurable gains: shorter downtime windows, faster procurement cycles, improved production forecasting, and tighter compliance with audit trails and cybersecurity protocols.