For over seven decades, Ameeri Industries has stood as a pillar of manufacturing excellence, forging a massive enterprise that encompasses everything from specialized electrical solutions to heavy-duty road safety products. Their success is built on constant development, but this very history of expansion led to a critical challenge: a constellation of disparate, outdated legacy systems that could no longer keep pace with their complex, modern operations.

The mandate for Lexubrix was clear: modernize the entire operational backbone—integrating manufacturing, supply chain, and finance across three distinct brands—without causing a single hour of unplanned downtime. In an industry where a pause in production means immense financial loss and broken contractual commitments, the risk was profound.

The Giant's Anatomy

To understand the complexity of the challenge, one must understand the diverse nature of Ameeri's brands:

  • AMETECH The largest panel manufacturing facility in Bahrain. Deals with high-volume electrical switchgears, complex Bills of Materials, and automated powder coating.
  • AMELITE A premium lighting brand dealing with fast-moving consumer goods (luminaires, floodlights) requiring rapid product introduction cycles.
  • AMGARD Heavy fabrication focus (guard rails, street poles). Requires robust scheduling for hot-dip galvanizing, shot blasting, and industrial production.

The Challenge of Complexity and Continuity

These three business units operate within vastly different environments. While Ametech requires precision for switchgear components, Amgard deals with heavy fabrication processes like hot-dip galvanizing. Their old systems were siloed, preventing real-time data flow.

Inventory managed in one system didn't reflect accurately in the financial ledger until weeks later. Production planning lacked real-time feedback from the shop floor. This operational opacity resulted in decision fatigue, inventory errors, and manual reconciliation—a dangerous vulnerability for a company of this scale.

Lexubrix’s Zero-Downtime Strategy

To successfully modernize a seven-decade-old giant without disrupting its output, Lexubrix implemented a hyper-disciplined Phased Migration strategy, focusing on parallel operation and non-disruptive cutover.

1. The Digital Twin Phase

We first built a "Digital Twin" of the entire enterprise—a new, fully customized ERP platform (integrating Manufacturing Execution System (MES) and Supply Chain Management) running parallel to the legacy systems. Crucially, master data (products, vendors, customers) was meticulously cleansed and migrated first.

2. Modular MVP Rollout

We started the live implementation with the least disruptive business process: Financial Reporting. This ensured all core financial data was validated on the new platform while production continued on the old system. Once stable, we moved to Amelite's inventory management (a lower-risk area compared to heavy fabrication).

3. Surgical Cutover

The most critical processes—like Ametech's panel manufacturing and Amgard's heavy fabrication control—were switched over during non-peak holiday periods. This involved a "freeze and switch" where all data was reconciled, systems were validated, and the transition was completed within a tight, pre-defined window, minimizing exposure to potential failures.

Unlocking the Full Potential

The results of this transformation were immediate and tangible, uniting the three brands under a single, intelligent operational roof:

  • Ametech: Gained real-time production visibility. Managers now track work-in-progress (WIP) status, capacity utilization, and quality assurance from a central dashboard, leading to an estimated 15% reduction in manufacturing cycle time.
  • Amgard: Achieved optimized material planning. By connecting the sales pipeline directly to the new supply chain module, Amgard now automatically calculates raw material needs for steel and GI components, significantly reducing lead times and carrying costs.
  • Amelite: Accelerated time-to-market. The new Product Information Management (PIM) capabilities allow for rapid new product setup, enabling Amelite to respond faster to evolving LED and solar lighting market demands.
The Outcome By managing the complex intersection of heavy fabrication, electrical manufacturing, and product innovation with surgical precision, Lexubrix engineered a foundation for Ameeri Industries' next seven decades of growth.

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