Industrial Controls Manufacturer
Oil & Gas / Industrial Controls • New Implementation (System Architecture)
Engineer-to-Order Hybrid Manufacturing System Design Fortune 500 Acquisition
Designed complete NetSuite architecture for engineer-to-order manufacturer with custom BOMs and hybrid manufacturing model. Company later acquired by Fortune 500.
Timeline: 12-month implementation
Outcome
Architecture became foundation for successful 12-month implementation.
12 mo
Implementation completed on schedule
Acquired
Company later acquired by Fortune 500
Recruited
Client tried to hire me directly
The Challenge
This manufacturer produces electronic control systems for turbomachinery used in oil and gas, power generation, and industrial applications. Their manufacturing model pushed the boundaries of standard NetSuite implementations.
- ✕ Every control system custom-designed for specific turbomachinery applications
- ✕ Engineering specifications drove manufacturing—custom BOMs the norm, not exception
- ✕ Hybrid model: external partner for subassemblies, in-house final assembly
- ✕ Version control required between CAD/schematics and NetSuite BOMs
- ✕ Component specifications included tolerances (voltage, capacitance) requiring approval tracking
The Solution
Role: Senior Technical Consultant — System Design and Architecture
1
Custom BOM Architecture
Design phase- ✓ Designed flexible BOM structure for engineer-to-order requirements
- ✓ Built integration framework between CAD/schematic systems and NetSuite
- ✓ Created version control workflow for engineering changes with approval routing
- ✓ Established component specification tracking with tolerance validation
2
Manufacturing Workflow Design
Design phase- ✓ Mapped hybrid manufacturing model (external + internal) into NetSuite work orders
- ✓ Designed shop floor routing tracking both outsourced and in-house operations
- ✓ Built visibility dashboards for production status across all manufacturing stages
- ✓ Created integration architecture for shop floor data capture
3
Financial Integration
Design phase- ✓ Designed costing model capturing actual vs. standard costs for custom builds
- ✓ Built project-based accounting structure for large custom orders
- ✓ Established inventory valuation methods appropriate for engineer-to-order
Key Takeaways
- → Manufacturing complexity requires architect-level thinking—not just configuration.
- → System design before implementation—designing for scale and flexibility pays off.
- → Integration matters—connecting engineering systems, shop floor, and financials.
- → Sometimes the best outcome is building something worth acquiring.
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