Manufacturing ERP & WMS Bridge
A manufacturer rolled out a modern cloud warehouse system while production planning and finance still ran on a long-established ERP. Overnight file drops and spreadsheet reconciliations could not keep up with same-day shipping promises to large retail customers. Operations needed reliable, visible synchronization between the two worlds.
Business impact at a glance.
Order-to-ERP acknowledgment error rate fell from 2.3% to 0.18%.
Overnight reconciliation batches reduced from seven to two non-critical jobs.
Mean time to detect integration failures improved from hours to minutes via alerting.
Peak-season shipping days completed without manual “bridge” spreadsheet interventions.
Development team velocity for new message types improved with shared templates and tests.
Business Challenge
- Order and shipment updates sometimes arrived in the wrong order between the warehouse system and the ERP.
- The same warehouse event could post to finance twice, with no reliable way to detect duplicates.
- ERP maintenance and peak shipping windows collided; when something failed, teams needed a safe way to retry without corrupting data.
- When message queues backed up, there was no clear operational picture of what was stuck or why.
- New services had to run in containers and respect existing network boundaries (DMZ, VPN) and security standards.
Our Approach
We placed a dedicated .NET 8 integration layer between the warehouse platform and the ERP, using the client’s approved RabbitMQ cluster for messaging. Each message carried stable business identifiers; because delivery can repeat in real systems, we stored deduplication data in SQL Server so finance never saw the same logical event twice. Hangfire ran scheduled checks and dead-letter inspection. A small Blazor operations console gave IT and supply-chain leads queue depth, failures, and controlled replay—with guardrails so retries stay safe.
Phase 01
Discovery & alignment
Workshops, process and systems review, success metrics.
Phase 02
Design & planning
Architecture, experience and workflow design, delivery plan.
Phase 03
Build & validation
Implementation, integration, testing, demos, refinements.
Phase 04
Go-live & enablement
Controlled rollout, training, handover, post-launch tuning.
What We Delivered
- Canonical message schemas for order release, pick confirmation, shipment, and inventory adjustment.
- Outbox pattern from WMS-facing APIs to ensure publish reliability.
- Retry policies with exponential backoff and poison-message quarantine.
- Hangfire dashboards restricted to operations roles for controlled reprocessing.
- Health checks and metrics endpoints integrated with existing Prometheus and Grafana.
- Documentation and handover for on-call rotation and ERP cutover windows.
Technology Stack
The bridge stopped being a black box. We see failures, we replay safely, and finance trusts the numbers again.
Director of IT, Supply Chain
Manufacturing
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