Clark Solutions — Production Management & ERP Reimplementation
Engineering-Production Alignment, Cost Governance, and Systemic Structuring
Overview
Managed and structured industrial operations by integrating Engineering, Production, costs, logistics, and ERP to improve information flow, operational organization, and management visibility.
The Systemic Challenge
The operation faced gaps between Project Engineering and Production, along with dispersed operational information, making standardization, cost tracking, and production-flow coordination more difficult.
- Inconsistencies between engineering blueprints and factory floor manufacturability.
- Underutilized ERP system with fragmented data across shadow spreadsheets.
- Inability to calculate accurate hourly rates and direct/indirect overhead allocation.
The Solution Blueprint
Redesigned the flow between Engineering and Production by creating Industrial Engineering, reimplementing the ERP as the operational core, and structuring labor-hour, cost, and logistics controls.
- Formed the Industrial Engineering department to validate manufacturability and structure accurate BOMs in the ERP.
- Reimplemented the ERP, enforcing daily labor hour tracking mapped to specific work orders.
- Designed a new cost center architecture, hourly labor rates, and rigorous inventory controls.
- Created and structured the Logistics department to ensure timely material staging and handling.
Results & Evidence
Impact & Operational Outcomes
- Improved integration between Engineering and Production through Industrial Engineering.
- Centralized operational information in the ERP, including labor hours, costs, and cost centers.
- Structured logistics and operational controls to support monitoring of production, capacity, costs, and priorities.
Methods & Tools Utilized
Process-driven management combining operational structuring, ERP usage, and production and cost controls.
- One unified source of truth for both operational and financial data.
- Industrial engineering as the bridge between engineering theory and shop-floor reality.