Case Study 2 - Manufacturing
Transforming Global Manufacturing Operations: Konexxia's Data Migration Excellence
A Dynamics 365 Data Migration Success Story
Introduction
When a global component manufacturer with 3,000 employees found their previous ERP implementations mired in extended hyper-care and business disruption, they turned to Konexxia for their Eastern European rollout.
Facing the daunting challenge of migrating complex manufacturing and warehousing data from legacy BPCS systems to Dynamics F&SCM across five countries, all within 12 months, Konexxia delivered what previous teams couldn't: flawless data migration, cutover time reduced from several weeks to a single weekend, and hyper-care slashed from months to just six weeks.
This wasn't merely a technical success but a business transformation that the client's Programme Lead described as "the smoothest transition they had ever experienced." A Dynamics 365 Data Migration Success Story!
Client Profile
A global component manufacturing company with 3,000 employees worldwide was struggling with an outdated BPCS system running on AS400 technology. The legacy system had become unsupportable and lacked modern integration capabilities, significantly hampering their operational efficiency and business intelligence efforts.
The Challenge
The client was in the midst of a phased global Dynamics F&SCM implementation that had already encountered serious difficulties.
Previous go-lives in France and Spain had
resulted in extended hyper-care periods due
to data migration issues stemming from:
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Poor documentation of requirements
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Inadequate data quality in source systems
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Inconsistent migration methodologies
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Excessively long cutover periods (2-3 weeks)
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Business disruption requiring dual maintenance procedures
With five Eastern European countries scheduled for implementation within a strict 12-month timeframe, the company needed a robust solution to avoid repeating past mistakes.
Konexxia's Approach
Konexxia applied their structured 6-step methodology to bring order and efficiency to the data migration process:
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Deep-Dive Data Discovery: Comprehensive analysis of legacy BPCS and CRM systems, with particular attention to complex warehousing and manufacturing data
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Structured Documentation: Creation of detailed mapping documents from previously inadequate documentation
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Issue Management: Implementation of a rigorous tracking system using Azure DevOps to identify upstream factors affecting data quality
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Automation: Deployment of Konexxia's proprietary Generix data platform to:
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Automate extraction from legacy systems
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Generate target load structures aligned with Dynamics data entities
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Execute deterministic transformations
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Perform multi-threaded loading
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Expert Team Deployment: Assignment of five specialists with extensive ERP migration experience, strategically allocated to specific Dynamics functional areas
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Validation Framework: Development of automated validation processes to check against target configuration and identify configuration, data quality, referential integrity or duplication issues
Implementation Process
Konexxia established a systematic validation cycle where
data was:
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Extracted at key month-ends
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Transformed according to mapping rules
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Validated through automated checks
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Loaded into test environments
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Reconciled using the Generix platform
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Verified by users through guided processes
All issues were systematically logged and
tracked to resolution, ensuring continuous quality
improvement throughout the project lifecycle.
Four of these cycles were executed periodically
ahead of cutover, allowing us to continuously improve
data quality, get accurate migration timings and
train the users in appropriate data validation processes.
Transformational Results
Konexxia's structured approach delivered remarkable improvements over previous implementation phases, transforming what had been a troubled global ERP rollout into a showcase of implementation excellence:
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Strategic Business Outcomes
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On-Time, On-Budget Delivery: All five Eastern European countries went live within the 12-month timeframe, allowing the business to maintain its strategic digital transformation roadmap without costly delays. This predictable delivery restored stakeholder confidence in the overall programme.
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Reduced Hypercare Period: Support requirements dropped dramatically from "many months" in previous implementations to just 6 weeks, freeing valuable IT and business resources to return to normal operations and focus on leveraging the new system capabilities rather than resolving issues.
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Minimal Business Disruption: The cutover period was reduced from an unmanageable 2-3 weeks to a single weekend. This 85% reduction in transition time eliminated the need for extended dual maintenance processes, dramatically reducing the risk of data synchronisation errors and allowing business users to quickly adapt to the new system.
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Improved Data Quality: Comprehensive validation methodology ensured clean, accurate data at go-live, with reconciliation reports showing 99.8% accuracy across all critical data elements. This dramatically improved user confidence in the new system and eliminated the data-related errors that had plagued previous implementations.
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Operational Efficiencies
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Accelerated Loading Performance: Konexxia's multi-threaded loading approach improved data migration speeds by over 300%, allowing complex data transformations to complete within a fraction of the time required by previous methods.
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Reduced Manual Effort: Automated validation processes eliminated approximately 600 person-hours of manual checking that had been required in previous implementations, simultaneously improving accuracy and freeing resources for higher-value activities.
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Clear Issue Resolution Path: The structured issue management framework implemented in Azure DevOps provided complete visibility of data-related challenges, with 97% of identified issues resolved before go-live, compared to just 65% in previous implementations.
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Long-Term Value
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Repeatable Methodology: The success of this implementation established a proven template for remaining global regions, creating a predictable pathway to complete the worldwide rollout.
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Knowledge Transfer: Detailed documentation of the migration approach enabled the client team to build internal capabilities, reducing dependency on external consultants for future phases.
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Business Confidence: The dramatic improvement in implementation quality rebuilt trust between IT and business stakeholders, creating a more collaborative environment for future digital transformation initiatives.
Client Endorsement
"Konexxia consistently demonstrates exceptional thoroughness and reliability, regardless of the complexity or demands. Their professional consultative approach sets them apart, but what truly distinguishes them is their unwavering commitment to delivering results. I would not hesitate to engage their services again."
Ollie McComb, Client Programme Lead
Key Success Factors
Methodical Approach:
Structured 6-step methodology ensured no critical aspects were overlooked
Proprietary Technology:
Generix data platform provided automation capabilities that dramatically reduced manual effort and error potential
Expert Team:
Specialists with deep functional
knowledge ensured accurate mapping and transformation
Validation Discipline:
Rigorous multi-stage verification processes identified
and resolved issues before they could impact the business
This implementation demonstrates how Konexxia's specialised data migration expertise can transform challenging ERP projects into Dynamics 365 Data Migration Success stories, even in complex global manufacturing environments with tight deadlines and previous implementation challenges.