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MANUFACTURING

Why does your ERP say one thing, and your floor say another?

It is the same job, re-keyed from screen to screen, which is why most shops use only 44% of the data they already collect. You don’t have a data problem, you have a connection problem. Eligeo connects your systems from RFQ to invoice, and puts AI on the manual work between them. You keep the ERP you run.

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44%

of the data you already collect is actually used

Rockwell Automation / Plex, 2024

~70%

of manufacturers name disconnected, low-quality data as the No. 1 barrier to their AI plans.

Deloitte / Mfg Leadership Council

70%+

of ERP implementations miss their original business case
Gartner, via ECI

95%

are using or evaluating smart-manufacturing tech, intent is not the problem
Rockwell Automation / Plex, 2024

WE KNOW YOUR PROCESS, FROM RFQ TO INVOICE

It is one job. You just run it six times, by hand.

Quote and RFQ, engineering and BOM, planning and buying, the shop floor, quality and shipping, costing and invoice. Each stage runs fine on its own. The margin leaks in the handoffs between them, where a number gets re-typed from one system into the next. The line in red is what each stage looks like before the systems are connected.

01 · SALES

Quote / RFQ

Scope, material and hours priced against what the last run actually cost.

Today, before the systems are connected: Priced from the last job’s spreadsheet and an engineer’s memory.

02 · ENGINEERING

BOM & routing

One current revision, visible to planning the moment it is released.

Today, before the systems are connected: Revisions live in CAD, in the ERP and in someone’s inbox.

03 · PLANNING

Schedule & buy

Scheduling and purchasing read the same on-hand and open-PO record.

Today, before the systems are connected: MRP run against on-hand numbers nobody fully trusts.

04 · SHOP FLOOR

Work order run

Run time, labor and scrap land on the work order as they happen.

Today, before the systems are connected: Actuals written on a paper traveler, re-typed into the ERP a shift or a week later.

05 · QUALITY

Inspect & ship

Inspection results and certs attached to the order, not a folder.

Today, before the systems are connected: Inspection sheets and certs filed outside the system.

06 · FINANCE

Cost & invoice

Real job cost closes the loop back into the next quote.

Today, before the systems are connected: Job cost reconstructed weeks after the parts shipped.

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SOUND FAMILIAR?

Six things every plant lives with, and quietly pays for on every job.

!

Data you collect but never use

Machines and people generate more data than ever, and only about 44% of it is actually used. The raw material for automation exists, it is just trapped and messy.

!

The ERP does not match the floor

The ERP shows what was supposed to happen. The whiteboard shows what is actually happening. The two are never reconciled.

!

Systems that do not talk

Where the ERP, CAD, quality and the spreadsheets do not connect, a person bridges them, and the same production number gets entered more than once.

!

Rollout scar tissue

A past ERP or platform project that missed its business case, on budget or on promise, and left the team wary of the next big bet.

!

Costing after the fact

Run time, labor and scrap reach costing late or by hand, so job cost is reconstructed weeks after the parts shipped, not known as they run.

!

Compliance by hand

Quality and safety documentation is kept manually, outside the system, so an audit would surface gaps nobody knew were there.

THE SAME JOB, CONNECTED

Quote from real cost. Cost jobs as they run.
Ship audit-ready.

The same six stages, run as one connected chain from RFQ to invoice. Here is what your estimators, planners, floor and finance team feel within the first cycles, without touching the ERP you already run.

One order record, RFQ to invoice

Quote, BOM, schedule, floor actuals, quality and cost live on one connected record, so the job stops being re-keyed from screen to screen.

Actuals reach costing on time

Run time, labor and scrap land on the work order as they happen, so job cost is known as the job runs, not reconstructed weeks later.

BOM and routing land clean

A released revision is visible to planning the moment it changes, so a late BOM stops cascading into a bad schedule and bad parts.

Use all your data, not 44%

The data you already collect gets connected and put to work, which is what makes AI reachable instead of stalled on messy inputs.

Keep the ERP you already run

We connect your ERP, MES, CAD, quality system and spreadsheets. No two-year rip and replace, no new platform the floor has to learn.

AI does the copy-paste

AI reads RFQ drawings and specs, checks the BOM, and pulls inspection results and certs into the record, taking over the manual work between systems.

THE COST OF STANDING STILL

What one more year of disconnected data actually costs you.

The losses are already on your P&L, they just don’t have a line item. The gains are what the industry’s own research says is on the table the moment the process gets connected.

STAY AS YOU ARE

44%

is all the data you collect that actually gets used, the rest stays trapped in disconnected systems.

Rockwell / Plex, 2024

~70%

of your AI ambitions stay blocked by data that is not connected, clean or in context.
Deloitte / Mfg Leadership Council

70%+

are the odds a big-bang ERP rip-and-replace misses its original business case.
Gartner, via ECI

50%

of ERP projects end up needing unplanned extra technology, and 23% blow the budget.

Panorama Consulting, via ECI

CONNECT THE PROCESS

44→all

the data you already collect, connected and usable, which is what makes AI reachable.
Rockwell / Plex framing

~20%

efficiency gain reported after moving off manual data collection.
MachineMetrics, vendor-reported

0

systems replaced. You keep the ERP you run, we connect it to the floor.
Eligeo delivery model

Real-time

floor actuals reaching costing and planning as they happen, not a shift or a week later.
Eligeo estimate, comparable builds
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HOW ELIGEO WORKS · THE CORE METHOD

From the first call to a plant running on connected data, one method.

Consult, Optimize, Rapid Deploy, Engage. It is the discipline behind every build we run, and the one we ran on ourselves first. Here is exactly how your project moves through Eligeo, start to finish.
C
Consult

We read the floor, not just the ERP screen.

It starts with a Process Audit. We sit with your operations, planning and quality people, walk your real flow from order to ship, and highlight where the data goes stale and the hours leak. The audit fee is credited into the implementation if you decide to proceed with us.

O
Optimize

We design the fix around your process.

From what the Process Audit reveals, we build the strategy to optimize, integrate and bring AI into your processes, through Process Architecture. You know the price and the plan before any work starts.

R
Rapid Deploy

We build it and prove it on a live line.

We connect your ERP, MES and spreadsheets, put automations and AI agents on the manual work between them, test it on a real production area, and hand it over built, tested and documented.

E
Engage

We make sure the floor actually uses it.

We measure adoption against a target, train the office and the floor, and keep re-aiming as your business and your systems change. We stay with your team for as long as you need and monitor adoption, so your investment pays off.

One continuous loop, re-aimed on every line and every shift
AI Foundations · the hidden risk

Your team is already using AI. Do you know what they’re feeding it?

Right now, someone in your business is pasting a contract, a customer list or your numbers into ChatGPT, Gemini, Copilot or Claude, on a personal account your company does not own, cannot see, and cannot switch off. It is called shadow AI, and it is the quiet risk under the whole conversation.

Before you read on, ask yourself
  • ?Which AI tools is your team actually using, and on whose account?
  • ?What company data has already been pasted into them?
  • ?Could you prove to a client or auditor where that data went?
  • ?What happens to that access the day someone leaves?

Not sure of the answers? That is exactly the point, and you are not alone. The fix is not a ban. On the AI Foundations page we show you how we demystify it: the full picture of what AI can safely do for your business, and how we get it owned, secured and actually working, with real skills built by Eligeo doing the job so your data never has to leave your control.

See how AI Foundations works → Book a Discovery Call Built onClaude

BUILT ON PROCESS, PROVEN ON OURSELVES FIRST

We start on your floor, not in a slide deck.

We are a monday.com Platinum Partner and Make Silver Partner, and we ran this method on our own operations before we recommended it to anyone else. So we start by mapping how your plant actually runs, quote, floor, ERP and quality, and design the fix around that reality, not around a demo. You get a partner who cares whether the floor actually uses it, and stays until it does.
Know more about Eligeo

QUESTIONS OPERATIONS LEADERS ASK US

What manufacturers ask before they start.

Why doesn’t our ERP or MES reflect what is actually happening on the floor?

Usually the floor data is entered late, entered twice, or never makes it back at all, so the ERP describes the plan while the whiteboard describes reality. Eligeo captures events once, at the source, and connects the floor to the system so the two reconcile continuously instead of at month-end.

It depends on your stack and on whether you already have one system acting as the single source of truth, so the starting point is deciding what data each tool owns and where the truth should live. Once that is clear, an integration layer keeps everything in sync and AI handles the manual reconciliation between systems. Eligeo maps this first through a Process Audit and Process Architecture, and where it makes sense we set up a single-source-of-truth platform plus an integration platform, with AI on top to remove the manual job, without replacing the tools you already run.

Let the systems report status instead of people. Output against plan, downtime, scrap and open work orders get pulled from where the work happens onto one dashboard, so you see the floor as it runs instead of reading about it next week. The key is capturing each event once, at the source, so the data is live rather than re-keyed at the end of the shift. Eligeo connects your ERP, MES and the tools you already run, and builds that live dashboard on top of one connected record, so leadership sees the floor in real time without a single status call.

Capture the process, not just the person. Setups, checks and troubleshooting go into a system the next operator can search, and shift handover becomes a record instead of a conversation, so a retirement stops taking your operating memory with it. The goal is to make the knowledge live in the workflow, not in someone’s head. Eligeo helps you turn that tribal knowledge into connected, searchable process on the tools you already run, and uses AI to capture and surface it as the work happens, so the know-how stays even when the person moves on.

Yes, and it should not mean another login. Good AI sits on top of the tools you already run and does the manual work between them: reading RFQ drawings and specs, checking the BOM against the quote, and pulling inspection results and certs into the record. Keep a person reviewing anything that drives a price or a compliance obligation, at least at first. Eligeo builds exactly this on your existing stack, putting AI and automation on the handoffs, so your team keeps working the way they know while the copy-paste disappears.

It can capture inspection results, draft non-conformance records and assemble the pack an auditor asks for, with a person reviewing anything that carries a compliance obligation. The order matters: standardize how the data is captured on the floor first, then let automation build the records from it, otherwise you are just automating a mess. Eligeo sets this up on your own quality and safety processes, connecting the capture to your systems and letting AI assemble the records as work happens, so the next audit is an export instead of a scramble.

Start by mapping where the data actually breaks before buying anything, so spend follows proven value instead of a generic budget. A short diagnostic that quantifies the opportunity is the lowest-risk first move, and it is built to deliver in stages, so you see the first connected outcomes early instead of waiting for one big finish. With Eligeo that diagnostic is a Process Audit, and, when the systems need a target picture, a Process Architecture. The audit fee is credited into the build if you move forward, so you are not paying twice to find out where to begin.

Probably not on ambition. 95% of manufacturers are already using or evaluating smart-manufacturing tech (Rockwell / Plex). The real gap is data readiness: manufacturers use only about 44% of the data they collect, and around 70% name disconnected, low-quality data as the biggest thing blocking AI (Deloitte / Manufacturing Leadership Council). So the move is not to buy more AI, it is to connect and clean your data first. Eligeo does exactly that, starting small and proving value, so your AI plans become reachable instead of stalled.

AI capability and your own priorities move faster than any fixed project scope, so the systems you connect this year will need re-aiming next year. The healthiest pattern is a continuous cycle: review what changed and what is newly possible, pick the next priority, build it, measure adoption, and repeat, rather than writing a new project every time. That is what Eligeo Momentum is for: we keep directing your roadmap month to month while your team builds, with a living list of next-best moves and a monthly allowance for smaller asks, so improvement never stalls waiting on a new proposal.

This is the real risk with connected systems: a renamed field or a repointed board can silently stop an automation, and you often find out weeks later when something downstream goes wrong. The answer is not a support desk you call after the fact, it is continuous monitoring that reads the system on a schedule and flags drift the moment it happens, with the business impact attached. Eligeo Safeguard does this, it watches your system, tells you in plain language what broke and what it is costing, and fixes it, so nothing silently costs you without your knowledge.

Before connecting or automating, it helps to have an honest baseline: what systems you run, how they are configured, where they are fragile, and how complex the environment really is. That baseline keeps everyone working from the same map and stops you from automating on top of a shaky foundation. Eligeo starts with a Platform Audit, a structured read of your current setup that produces that shared baseline, so every decision after it, connect, automate or add AI, is made on evidence instead of assumption.

2-minute check

Where should your plant start?

Three questions. We’ll point you to the first move that pays back fastest.

See exactly where your jobs fall into the cracks.

Bring us your flow from RFQ to invoice. We will show you where the data breaks and the time leaks, and what it takes to connect it. No rip-and-replace.
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