Old system must go; vendors demo scheduling optimization and digital twins— the floor asks whether they can report work and issue material tomorrow. Phase one scoped on "advanced features" turns cutover into downtime. Iron rule for replacement: keep continuous production—work orders, reporting, inventory, quality records run on old definitions first; optimize later. Advanced features in phase two, validated on real data—not on cutover day as a lab.
Keeping continuous is not conservatism—it is basic respect for the line.
Phase One Migrates Skeleton Only
Skeleton: release and close work orders, kitting and issue, reporting and defects, basic trace. UI can look old; definitions must match finance and warehouse. Parallel run needs a hard exit date—but until then old system must cut back. No cutback drill, no cutover.
- Cutover in slow season or long weekend; reserve rollback staff.
- New feature switches default off; open by unit gradually.
- Train by role for "how to work today"—not module manuals.
Advanced Features Validate on Production
Scheduling optimization, predictive maintenance—open after skeleton stable two weeks. The XYN digital intelligence system aligns work orders and inventory first; smart modules can lag. Continuous production earns new UI; one outage and even advanced features get uninstall requests.
Put "no line stop" as acceptance item one. Pass that—other features can negotiate.
