How to Solve Post-Implementation ERP Challenges in the Manufacturing Industry

Quick Summary 

1. Boosts User Adoption – Continuous training and role-based guidance help employees shift from manual processes to ERP usage with confidence.

2. Improves Data Accuracy – Regular audits and clean-up reduce errors in reporting, forecasting, and compliance.

3. Choose the Right ERP Software – Select an ERP that fits your industry, GST compliance, and business needs.

4. Aligns Processes Efficiently – Reviewing workflows and limiting over-customisation keeps ERP scalable and effective.

5. Delivers Measurable ROI – Tracking KPIs like inventory turnover, order fulfilment, and production efficiency shows tangible business value.

Many times, when an ERP system implementation for manufacturing has been fully completed, businesses feel relieved that the most challenging phase has passed. But, in reality, it is after the go-live that the real journey starts. Improper management of post-implementation ERP challenges like user adoption, process alignment, data accuracy, and performance issues can drag down that uncorked growth. This article will discuss: Post Implementation ERP Challenges Experienced by Manufacturers after Implementing ERP for Manufacturing in India, and their Feasible Strategies. Difficult tasks face an entrepreneur upon implementing Enterprise Resource Planning; read and find ways how Indian manufacturing enterprises solve these issues after ERP implementation in manufacturing.

 

Why Post-Implementation Challenges Are Common in Manufacturing

Manufacturing is a complex industry where multiple processes, procurement, production, quality control, inventory, and distribution need to run in sync. When an ERP goes live, the system forces organisations to adapt to a new way of working. This transition, though beneficial in the long run, often comes with obstacles such as:

• Staff resistance to change.
• Unclear workflows due to poor process mapping.
• Gaps between system features and actual business requirements.
• Data migration errors that affect reporting.
• Delays in production due to unfamiliarity with the system.

Key Post-Implementation ERP Challenges in Manufacturing

1. User Adoption and Training

One of the biggest hurdles is getting employees to fully adopt the ERP. Operators, supervisors, and managers may continue to rely on old habits like spreadsheets or manual records. Without consistent training, the ERP becomes underutilised.

Solution: Conduct refresher training sessions and create role-based user manuals. Encourage employees by showing them how the ERP simplifies daily tasks such as material tracking or production planning.

3. Integration with Existing Systems

Manufacturing organizations in India make use of third-party payroll software, GST compliance, or vendor portals. After the implementation, if the current ERP was never aligned with these tools, then integration issues are bound to occur.

Solution: Collaborate with the ERP vendor to create seamless integrations. APIs and customized connectors will help reduce manual work that has to be done and maintain the consistency of data across platforms.

4. Process Alignment and Customisation Needs

The standard ERP functionalities sometimes do not correspond to a company’s specific processes, and hence, inefficiencies or workarounds.

Solution: Map processes thoroughly and identify gaps. If customized, ensure it is done with long-term scalability. Too many customizations bring complexity with future upgrades.

5. Measuring ROI and Performance

After having burnt time and money on ERP implementation, manufacturers sit back with folded arms waiting for a quick ROI. The benefits of ERP take time to reflect; most times, they sow discontent.

Solution: Define major performance indicators like production efficiency or order fulfillment time, inventory turnover, before implementation. Monitor them regularly to see progress and measurable benefits.

Best Practices to Overcome Post-Implementation ERP Challenges

Solving post-implementation hurdles is not just about fixing issues; it’s about creating a culture where ERP becomes a natural part of day-to-day manufacturing operations. Here are some best practices that work well in the Indian manufacturing context:

1. Invest in Continuous Training

ERP isn’t a “set and forget” system. Ongoing training is required for new features, updates, and changes in business processes. Periodic workshops, video tutorials, and role-based sessions help boost the confidence of staff and reduce dependency on external consultants, while Indian factories see high turnover among employees; hence, periodic onboarding sessions for newly joined employees.

2. Establish an Internal ERP Support Team

Depending only on vendors for support will delay the resolution of issues at times. Having a small in-house ERP team will help troubleshoot basic data corrections, workflow issues, and more, on the spot. It will be the end-user to vendor (for problems beyond the end-users’ capacity) interface

3. Embrace Change Management Early

Resistance to change is natural. Some employees might prefer manual registers or spreadsheets, even after ERP rollout. Transparent communication from leadership is vital to explain why the system is beneficial, celebrate small wins, and reward departments that adapt quickly. When staff see real benefits, adoption rates improve.

4. Regular Data Audits and Process Reviews

A typical reason for the failure of ERP after implementation is due to inaccurate data entry or running old workflows. Carry out monthly audits on inventory, financial entries, and supplier records to ensure that the ERP keeps giving you good insights. Process reviews help identify bottlenecks so that operations become smoother over time.

5. Avoid Over-Customisation

It is very tempting to customize ERP according to every old practice, but too much customization makes upgrading harder and more expensive. Use standard features and functionalities as much as possible- customize only where it really adds value. For an Indian manufacturer, that should probably be in the areas of GST compliance, inventory management, and production planning.

6. Set Measurable KPIs from the Start

Define success clearly, for instance, in terms of how one measures reductions in raw material wastage, improvements in on-time deliveries, or fast order processing. The more of these outcomes you can measure, the more easily you prove ROI to the stakeholders and keep a significant ERP-user-improvement-momentum rolling.

7. Stay Connected with Your Vendor

Strong vendor partnerships are a must for this. The updates are released, along with the patches and new modules, by the ERP providers quite frequently. Connecting will keep your system in the best order in terms of security, compliance, and currency. For instance, in a country like India, where there are frequent changes to compliance requirements like GST and e-invoicing, it would be quite expensive if not handled correctly; timely vendor support ensures that such issues do not occur. If you are planning to implement ERP, it might be beneficial to have a look at my 10 Essential Steps for Successful Business ERP Implementation.

Conclusion

ERP implementation in manufacturing always has post-go-live challenges. The secret is not in considering them failures but as avenues for further fine-tuning. This is a perfect illustration of the fact that the ERP can, indeed, transform your manufacturing operations, provided there is adequate training and process alignment, and support.

Don’t handle ERP or its post-implementation challenges on your own. Find out how TejoERP can help your business grow – request a Free Demo today!.

Frequently Asked Questions:

1. What are the most common post-implementation ERP challenges in manufacturing?

Common challenges include user resistance, data inaccuracy, poor system integration, process misalignment, and difficulty in measuring ROI.

2. Why do employees resist ERP adoption after implementation?

Employees often resist ERP because they are used to manual methods or spreadsheets, and may find new systems complex without proper training.

3. How can manufacturers improve user adoption of ERP systems?

Regular training, role-based manuals, leadership communication, and showcasing daily benefits help increase adoption rates.

4. What steps can be taken to ensure ERP data accuracy after go-live?

Conduct frequent data audits, assign data ownership to departments, and use validation tools to eliminate duplicate or outdated records.

5. How does ERP integration affect manufacturing companies in India?

Without smooth integration with payroll, GST, and vendor systems, companies may face compliance delays, manual work, and data inconsistencies.

6. Should manufacturers customise ERP systems after implementation?

Limited customisation is fine, but over-customisation can complicate upgrades. Focus on aligning processes with standard ERP features first.

7. How long does it take to see ROI after ERP implementation in manufacturing?

ROI varies by company size and scope but typically takes 6–18 months, depending on training, adoption, and process efficiency.

8. What role does change management play in ERP success?

Change management helps reduce employee resistance by communicating benefits, setting expectations, and encouraging adoption at every level.

9. Why are KPIs important in post-implementation ERP monitoring?

KPIs like production efficiency, delivery times, and material wastage track ERP performance and demonstrate measurable improvements.

10. How can manufacturers in India overcome ERP compliance challenges?

Staying updated with GST and e-invoicing rules, working closely with ERP vendors, and enabling automated compliance modules help address challenges.