Manufacturing
Cloud ERP Migration & Automation for Nexon Manufacturing
Buraq migrated Nexon's legacy on-premise systems to a fully automated Odoo ERP on Azure, eliminating manual data entry, unifying 4 factory sites, and saving $3.2 M annually in operational costs.
Nexon Manufacturing Group
8 months
Primary KPI
$3.2M Annual Savings
Key measurable outcome
Tech Stack
Odoo 17Azure AKSApache AirflowPostgreSQLPower BITensorFlowMQTTPython
Tags
ERP MigrationOdooManufacturingIoTCloud InfrastructureProcess Automation
The Challenge
Problem Statement
Nexon Manufacturing Group operated four factory sites across two countries, each running a different combination of legacy ERP modules, Excel-based inventory trackers, and paper-based quality-control checklists. Financial consolidation at month-end required 12 business days of manual reconciliation. Procurement and warehouse teams had no shared visibility — stockouts on critical raw materials caused an average of 14 production-line shutdowns per quarter.
The leadership team had attempted two previous ERP migrations with other vendors, both abandoned mid-project due to scope creep and data-integrity failures. Confidence in digital transformation was low, and the mandate was clear: deliver a working system with zero production downtime during cutover.
The Solution
Our Approach
Buraq led a phased ERP modernisation programme anchored on Odoo 17 Enterprise hosted on Azure Kubernetes Service (AKS), with custom modules for shop-floor IoT integration and automated quality control.
Phase 1 — Discovery & Data Audit (6 weeks):
We conducted a full data-lineage audit across all four sites, mapping 420+ business processes and identifying 18,000 duplicate supplier records. A custom ETL pipeline built with Apache Airflow cleansed, de-duplicated, and migrated 6 years of transactional data into the new Odoo instance with full audit trails.
Phase 2 — Core ERP Deployment (12 weeks):
We configured Odoo modules for Manufacturing (MRP), Inventory, Purchase, Accounting, and HR across all sites with a unified chart of accounts. Custom Odoo modules were developed for:
• IoT-driven production tracking — PLC sensors on assembly lines push cycle-time and defect data directly into Odoo work orders via MQTT and Azure IoT Edge.
• Automated QC workflows — defect images captured by line cameras are classified by a TensorFlow model; non-conformances auto-generate corrective-action requests.
Phase 3 — Cutover & Hypercare (4 weeks):
A blue-green deployment strategy ensured zero downtime. Both systems ran in parallel for two weeks with automated reconciliation checks before the legacy systems were decommissioned.
Phase 4 — Advanced Analytics (6 weeks):
Power BI dashboards connected to the Odoo PostgreSQL layer provide real-time OEE (Overall Equipment Effectiveness), cost-per-unit trends, and supplier-performance scorecards.
Key Highlights
ERP Migration
Odoo
Manufacturing
IoT
Cloud Infrastructure
Process Automation
The Outcome
Results & Impact
Post-deployment metrics after 8 months in production:
• $3.2 M annual savings — elimination of manual data entry, reduced stockouts, and consolidated vendor negotiations.
• Month-end close reduced from 12 days to 2 days — automated intercompany reconciliation.
• 96% reduction in stockouts — real-time inventory visibility and automated reorder points.
• Zero production downtime during cutover — first successful ERP migration after two failed attempts with other vendors.
• 23% improvement in OEE across all four plants — IoT-driven insights enabled proactive line balancing.
• Full regulatory compliance — automated audit trails satisfy ISO 9001 and local tax authority requirements.
Nexon's CFO reported that the project paid for itself within the first five months of operation.
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