Client: Fictiv
Industry: Digital Manufacturing / Hardware Production
PRG Solution: Digital Transformation – PLM and ERP Implementation
“The urgency of this launch meant there was no margin for error. Product Realization Group’s ability to focus on exactly what was needed for day one, while keeping all teams aligned and engaged, was critical to our success. Their expertise in both Arena PLM and NetSuite ERP, combined with a collaborative, reductive, and agile approach, enabled us to meet an aggressive timeline and start production for three major customers to meet critical business goals.”
— Jim Ruga, Chief Information Officer, Fictiv
The Challenge
Fictiv had built its reputation as a leader in quick-turn prototype manufacturing. As its client base expanded, so did the opportunities for volume production, a new and critical business line. In 2024, as the company secured multiple deals to manufacture more complex mechanical assemblies, leadership recognized the need to expand its systems and process capabilities beyond the prototype business model.
The existing processes and systems, while optimized for speed and flexibility in supporting quick turn prototypes, lacked the controls, capabilities, and systems integration needed for higher-level assemblies, materials planning, inventory control, and quality management. The timeline was aggressive, with a hard go-live date of June 2025, driven by the urgency of three new production clients waiting to launch.
The Objective
Transform Fictiv’s operational systems to support a new production business line without disrupting the prototype business by implementing new Product Lifecycle Management (PLM) and Enterprise Resource Planning (ERP) systems and additional production processes that could scale to meet the company’s growth target for production deals in 2025.
The PRG Approach
PRG partnered closely with the Fictiv leadership and implementation teams to design and execute a “reductive project approach,” a strategic methodology focused on prioritizing core functionalities to ensure the June go-live date was met without compromise. This agile, collaborative effort allowed for parallel development and rapid output, focusing resources on the most critical path items to deliver a functional, working production process by the target date.
Key elements of the approach included:
- Parallel Development: The design, configuration, and data setup for the PLM and ERP processes ran concurrently to compress the timeline.
- Focused “Reductive” Methodology: Only essential processes required for day-one production support were prioritized, with expansion items deferred to a post-launch optimization phase.
- Strong Team Collaboration: PRG worked hand-in-hand with Fictiv’s internal teams, ERP implementation partner, and PLM vendor to align requirements, configurations, and workflows.
- Agile Execution: Executive support, frequent check-ins, rapid iteration, and in-sprint decision-making kept the project moving rapidly, with issues escalated and resolved in real time.
What We Delivered
By June 9, PRG and Fictiv successfully launched new PLM and ERP capabilities to support production manufacturing, including:
- PLM Processes: Part numbering and revision control, engineering change requests/orders, document control, supplier qualification, and approval workflows.
- ERP Processes: Sales order entry, purchasing, inventory management, production planning, MRP runs, and fulfillment workflows.
- Cross-System Integration: Automated data exchange from PLM to ERP for part master, approved vendor lists, and change control.
- User Enablement: Core team training, documentation, and post-go-live support to ensure a smooth transition.
The Results
- On-Time Launch: Systems went live on schedule, enabling Fictiv to begin production operations for three key customers per delivery needs.
- Improved Scalability: New processes and systems now provide a solid foundation for scaling targeted growth of production deals in 2025.
- Reduced Risk: Implementation of structured change management, supplier qualification, and inventory control processes mitigated the risk of production errors and delays.
- Faster Decision-Making: Streamlined workflows and real-time visibility into production data allow Fictiv teams to respond more quickly to customer needs.
Looking Ahead
This project is a testament to the power of strategic partnership and focused execution, turning an ambitious timeline into a significant business achievement. Fictiv is now well-positioned to become a dominant player in the volume production manufacturing space, with the systems and processes in place to support its rapid expansion.
With the foundation in place, PRG will continue to support Fictiv through the next Expand and Optimize phase, implementing quality management, additional ERP functionality, refining new production processes, training and development and enabling advanced reporting to further strengthen the company’s production capabilities, profitability and operational excellence.
