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Full-Scale ERP Transformation & Recovery

Multi-Site Engineered Packaging Solutions

17-location ERP implementation and Azure cloud migration across US, Mexico, and Canada. 26-month transformation delivering continuous value under "not to exceed" engagement model.

Client Type
PE-Backed Packaging Manufacturer
Scale
17 Locations (US/MX/CA)
Timeline
Dec 2021 – Mar 2024 (26 months)
Scope
ERP, Azure, Financial Systems
17
Locations Deployed
3
Countries (US/MX/CA)
9
Month Schedule Compression
100%
Go-Live Success Rate

Context

Multi-site engineered packaging solutions manufacturer requiring enterprise-wide ERP transformation following private equity acquisition and consolidation of multiple facilities. Existing systems fragmented across 17 locations with inconsistent processes, data standards, and reporting capabilities.

Constraint

Action

"What Have You Done For Me Lately?"

Implemented executive reporting methodology recognizing that leadership has short institutional memory during long transformations. Weekly value delivery summaries became major reset points, ensuring sustained support and budget alignment throughout the 26-month engagement.

This approach proved critical in maintaining stakeholder confidence and preventing scope creep as the program approached "not to exceed" thresholds.

Outcome

Strategic Value: This engagement demonstrated the viability of large-scale, multi-site ERP transformations under disciplined fixed-price models—proving that executive-focused value reporting and schedule compression techniques can deliver enterprise outcomes without cost overruns.

Program Overview

Program Timeline: December 2021 – March 2024

[Timeline Graphic - Overall Program Timeline Image Will Be Embedded Here]

Visual showing Wave 1 (Planning/MDM), Wave 2 (Implementation), and Wave 3 (Azure Migration) across 26 months

Phase 1: Initiation & Planning (Dec 2021 – Jun 2022)

Vendor Partner Selection

March 2022: Selected as vendor partner (SPG/Altamont) for comprehensive ERP transformation. Engagement structured as "not to exceed" fixed-price model, requiring precision in scope definition and schedule management from inception.

Business Requirements & Process Mapping

Conducted current-state workflow analysis across multiple business units:

Master Data Management Crisis

Critical Discovery: Product structures, material codes, and pricing data were fundamentally inconsistent across acquired facilities. This represented existential risk to ERP consolidation.

Response:

Phase 2: Wave 1 Deployment - Newark (Sep 2022)

First Go-Live: September 26, 2022 - SPS Newark implementation using Imaginera 3.1SR2 (on-premise) with cleaned data and standardized processes.

Strategic Decision: Newark served as proof-of-concept for deployment methodology before scaling to larger US, Mexico, and Canada facilities.

Phase 3: Azure Readiness & Wave 2 Planning (Oct 2022 – Dec 2022)

Schedule Compression Decision: May 2022 determination to compress original schedule by 9 months using "Lift and Shift" approach rather than phased migration.

Risk Acceptance: Accelerated timeline required simultaneous upgrade (Imaginera 3.2SR3), Azure migration, and multi-site deployment. Risk register maintained throughout (Newark-specific risks tracked).

Phase 4: Multi-Country Rollout (Jan 2023 – Apr 2023)

USA Cloud Go-Live

January 30, 2023: USA Azure Cloud implementation. Go/No-Go decision made January 20, 2023 following comprehensive UAT and third-party application integration testing.

Canada Cloud Go-Live

February 27, 2023: Canada Amtech Cloud SCRUM and deployment. Concurrent with USA stabilization and Mexico preparation.

Mexico Cloud Go-Live

March 23, 2023: Mexico UAT Amtech 3.2SR3 Cloud go-live. Most complex deployment due to cross-border regulatory requirements and manufacturing intensity.

Post-Go-Live Hypercare: Maintained through March 24, 2023 post-go-live review ensuring operational stability before proceeding to remaining sites.

Phase 5: Financial Systems Integration (Jun – Aug 2023)

June 7, 2023: Microsoft Business Central (MSBC) selected as financial bolt-on solution

August 3, 2023: MSBC implementation confirmed and integrated

August 25, 2023: Pricing functionality migrated into Amtech, enabling enterprise-wide pricing governance

September 1, 2023: Material Margin tracking operational at unit level across all sites

Phase 6: Final Sites & Program Closeout (Sep 2023 – Mar 2024)

September 4, 2023: Pacific Pulp Molding go-live (17th and final location)

December 22, 2023: Guadalajara facility de-construction completed (consolidation into primary Mexico operations)

March 2024: Program closeout, knowledge transfer to internal team, final documentation delivered

Continuous Value Delivery in Practice

Throughout the 26-month engagement, weekly executive reporting focused on:

  • Delivered Value This Week: Tangible milestones completed
  • Upcoming Milestones: Next 2-4 week visibility
  • Risk Status: Red/Yellow/Green with mitigation plans
  • Budget Tracking: "Not to exceed" threshold monitoring

This methodology prevented the common transformation failure mode where executive support erodes during long implementations. By resetting institutional memory weekly, program maintained budget authority and stakeholder confidence through inevitable challenges.

Program Documentation & Evidence

Selected artifacts demonstrating program complexity, execution methodology, and outcomes. Full documentation available in Evidence Room for authorized stakeholders.

Access Complete Documentation

Full PowerPoint decks, detailed timelines, metrics dashboards, and network diagrams available to authorized stakeholders in the Evidence Room.

Request Evidence Room Access

Measurable Results

17
Successful Go-Lives
0
Production Stoppages
100%
Deployment Success Rate
9
Months Accelerated

Operational Outcomes

Enterprise Data Standardization

Infrastructure Modernization

Financial Systems Integration

Program Management Outcomes

Schedule Performance

Budget & Scope Management

Knowledge Transfer & Sustainability

Strategic Significance

This engagement proved that large-scale, multi-site ERP transformations can be delivered under disciplined fixed-price models without sacrificing quality or scope. The "What Have You Done For Me Lately" methodology became a transferable framework for maintaining executive support during long implementations.

The combination of schedule compression (9 months), scope complexity (17 sites, 3 countries), and budget discipline (not to exceed threshold) demonstrates the viability of option-based leadership and continuous value delivery as transformation methodologies.

Lessons & Transferable Methods

  • Executive Memory Reset: Weekly value reporting prevents support erosion during long programs
  • Fixed-Price Discipline: "Not to exceed" models force precision in scope management and option framing
  • Schedule Compression Viability: Lift and Shift can work when risks are made explicit and accepted
  • MDM as Foundation: Data governance must precede deployment—no shortcuts
  • Wave-Based Risk Reduction: Newark proof-of-concept validated methodology before scaling