ERP Story | Modernizing a Configure-to-Order Manufacturer in Idaho
The challenge: A configure-to-order manufacturer operating five distinct companies and locations had outgrown a fragmented mix of QuickBooks, spreadsheets and a decades-old Microsoft Access application. The Access database contained critical product-configuration logic, but its original developer was no longer available to support it—creating both operational risk and a barrier to growth. AltiusERP implemented Microsoft Dynamics 365 Business Central as the company’s new ERP foundation.
Why it matters: Legacy systems often contain years of institutional knowledge. Replacing them isn’t simply a software migration; it requires identifying the business logic that must be preserved while eliminating the risk and inefficiency of unsupported applications.
The solution: AltiusERP created an integrated Business Central environment capable of supporting all five companies, including a purpose-built multi-entity management extension. Instead of employees moving between disconnected accounting systems and spreadsheets, the organization could manage its entities through a coordinated ERP environment with stronger financial, inventory and operational visibility.
Why it matters: ERP consolidation creates the most value when it connects operations—not just accounting. Bringing multiple entities onto a common platform can reduce duplicate work, improve data consistency and give management a clearer view across the organization.
The manufacturing challenge: This wasn’t a standard make-to-stock operation. Customer specifications determined product attributes and components, requiring the manufacturer to configure BOMs during the quoting process and carry those configurations through to production. AltiusERP replaced the legacy Access system with Product Configurator from Insightworks, integrating configurable BOMs directly with Business Central and creating a more connected quote-to-production workflow.
Why it matters: Configure-to-order manufacturing sits at the intersection of sales and production. If configuration data has to be manually recreated between quoting and manufacturing, complexity, delays and the potential for errors increase. Connecting configuration directly to the ERP helps turn customer requirements into actionable manufacturing information.
The final piece: Shipping was brought into the integrated environment with Dynamic Ship from Insightworks, supporting parcel and LTL shipments, freight rate shopping and shipping documentation. Together, Business Central, Product Configurator, Dynamic Ship and Multi-Entity functionality replaced a collection of QuickBooks files, spreadsheets and legacy applications with a more scalable platform connecting quote → configuration → manufacturing → inventory → shipping → financials.
Why it matters: The real benefit wasn’t any single application. It was the integration between them. Fewer disconnected systems meant fewer handoffs, better inventory visibility and a more streamlined path from customer order to finished product.
Lessons Learned
The big picture: Modernizing a manufacturing ERP environment doesn’t mean recreating every legacy process in new software. The better approach is to understand why the old process existed, preserve the business logic that creates value, and redesign everything else around an integrated platform.
Why it matters: Manufacturers can accumulate years—or decades—of spreadsheets, databases and workarounds. Successful ERP projects separate essential manufacturing knowledge from technical debt.
–Key Takeaways–
1) Don’t underestimate Legacy systems. An old database may contain critical product and manufacturing knowledge that must be understood before migration.
2) Design around the manufacturing process. Configure-to-order requirements should connect quoting, BOM configuration, production, inventory and fulfillment. This takes time!
3) Consolidate before adding complexity. A unified ERP platform can eliminate many spreadsheets, duplicate databases and manual handoffs.
4) Extend where it creates value. Targeted solutions for Multi-Entity Management, product configuration and shipping can address specialized requirements without rebuilding the ERP.
5) Integration is the multiplier. Connecting sales, manufacturing, inventory, shipping and financials creates more value than optimizing each function independently.
6) Manufacturing expertise matters. ERP configuration decisions—particularly around BOMs and Configure-to-Order workflows—require an understanding of both the software and how products actually move from customer specification to production. Choose a partner with a solid background in Manufacturing.
7) Change management is a huge challenge in companies with outdated Legacy systems. Begin the change management process early, ensure User Acceptance Testing has appropriate feedback loops and concerns are getting addressed quickly.