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Manufacturing ERP and Database Repair
We stabilized a troubled Firebird database and delivered ERP support for a manufacturer that builds its own electronics in-house.
Business goals
The client designs and makes sophisticated electronic hardware in its own facility and sells to demanding public-sector buyers. Its operations depended on a Firebird database, and that database was causing problems. For a manufacturer, an unreliable system of record affects purchasing, the shop floor and shipping all at once. The client needed the Firebird issues resolved and an ERP solution its people could rely on every day.
Project overview
Hexagon took on both sides of the problem. We investigated and resolved the client's Firebird database issues, then delivered ERP work on that steadier footing. That meant finding the causes, checking data integrity, and putting routine maintenance and backup practices in place. The ERP side covers the records a manufacturer runs on, including items, bills of materials, work orders and inventory, so the data stays trustworthy.
Challenges faced and solved
When a manufacturer's database misbehaves, the symptoms show up everywhere except the database.
Errors nobody could trace
Users saw slow screens, failed saves and odd records in the ERP. Each looked like a separate application bug, while the underlying cause sat in the database, so fixes kept missing the point.
We examined the Firebird database directly, using its own validation and statistics tools, to separate genuine data problems from application faults before changing anything.
Fear of losing production data
A repair done carelessly can make corruption worse. With inventory, build and purchasing records at stake, a manufacturer can't afford an experiment on its only copy of the data.
We worked from verified backups and tested repairs on a copy first, so production data was only touched once the method had been proven.
Performance decaying between fixes
Firebird keeps old record versions, and long-running transactions stop them being cleaned up. The database slows gradually, then someone restarts it, and the same thing starts all over again.
We reviewed transaction handling, sweep settings and backup and restore routines, targeting the conditions behind the slowdown instead of only clearing its symptoms.
An ERP that couldn't be trusted
If planners doubt the on-hand count, they keep their own spreadsheets. The ERP then stops being the system of record, and purchasing and build decisions rest on separate versions of the truth.
We delivered ERP work on the repaired database, keeping items, bills of materials, work orders and inventory together in one dependable set of records.
Features
| Feature | Description |
|---|---|
| Database health | |
| 1. Database Validation | Firebird's validation tools check pages and records for damage, showing what is actually broken before any repair begins. |
| 2. Controlled Repair | Faults are repaired on a tested copy first, then applied to production, which limits the risk to live records. |
| 3. Backup and Restore Testing | Backups are proven by restoring them, because an untested backup is only a hope. |
| 4. Transaction Review | Long-running transactions are identified and addressed, since they stop old record versions from being cleaned up. |
| 5. Sweep and Maintenance Routine | Housekeeping runs on a defined schedule, which helps keep the database from slowing down over time. |
| 6. Index and Query Tuning | Slow queries behind everyday ERP screens are reviewed, and indexes are adjusted where it helps. |
| 7. Data Clean-Up | Orphaned or inconsistent records are found and corrected, so reports reflect what's really on the shelf. |
| Operations and production | |
| 8. Item Master | Parts and finished goods live in one list with their key attributes, giving every department the same reference. |
| 9. Bills of Materials | Each assembly lists what goes into it, which supports accurate purchasing and build planning. |
| 10. Work Orders | Production jobs are recorded and followed from release to completion, so the floor and the office see the same status. |
| 11. Inventory Records | Stock levels update through receipts and issues, which gives planners a count worth trusting. |
| 12. Traceability Records | Build records can be looked up after the fact, which matters for electronics sold to demanding buyers. |
| Purchasing and management | |
| 13. Purchase Orders | Component orders are raised and received against the same records production uses. |
| 14. Stock Lookup | Staff can check availability of a part before committing to a build date. |
| 15. Operational Reports | Managers can pull reports on inventory and production from one source instead of separate spreadsheets. |
| 16. User Roles | Access is set by job, which reduces accidental changes to critical records. |
How the platform is put together
Each layer has one job.
The result
The client's Firebird issues were resolved, and its ERP work moved forward on a database its team could depend on.
| Area | Before | After |
|---|---|---|
| Database condition | Recurring Firebird issues disrupted daily work | Issues diagnosed and resolved at the database level |
| Data confidence | Staff had reason to doubt some records | Integrity checked, with bad records corrected |
| Maintenance | Problems handled as they surfaced | Backup, restore and sweep routines defined |
| ERP | An operating system held back by its data layer | ERP solution delivered on a steadier database |
How we took it from idea to launch
Good software follows a process. Here are the six stages, and what happens in each one.
Discovery & Requirements
Goal: Define the product vision, target audience and core business requirements.
Key activities- Stakeholder interviews
- Market and competitor research
- Defining user personas
- Drafting technical specifications or a Product Requirements Document (PRD)
Design (UX / UI)
Goal: Create an intuitive user experience and visual interface.
Key activities- UX design: information architecture, user flows and wireframes
- UI design: high-fidelity mockups and interactive prototypes in Figma or similar tools
- Design system: colors, typography and component libraries
Development: Frontend & Backend
Goal: Build the functional application using agile sprints.
Key activities- Backend: set up databases, design APIs (REST, GraphQL), implement server logic, and configure authentication and authorization (OAuth, RBAC)
- Frontend: build responsive interfaces and connect components to backend APIs
- Version control: manage code through Git and GitHub
Security & Optimization
Goal: Harden the application against vulnerabilities and boost performance.
Key activities- Security: address the OWASP Top 10, including injection, XSS and CSRF, enforce encryption in transit and at rest, and implement rate limiting
- Optimization: code splitting and lazy loading, database indexing, API caching and load testing
- QA and testing: unit, integration and end-to-end tests
Beta Release
Goal: Deploy to a controlled group of real users to catch edge-case bugs and gather feedback.
Key activities- Set up staging and production CI/CD pipelines
- Launch a closed or open beta with real users
- Monitor errors through observability tools
Public Release (Launch)
Goal: Roll the software out to the general public.
Key activities- Final production deployment
- DNS configuration
- Marketing and onboarding rollout
- Post-launch performance and security monitoring
Business benefits
Fewer database faults mean fewer interruptions to purchasing and production.
Clean data reduces the pull toward private spreadsheets.
Tested backups mean a restore is a known procedure, not a gamble.
Fixing the existing database avoided discarding years of operational history.
Conclusion
Firebird is still running inside plenty of manufacturing systems, often years after the people who set it up have moved on. When it starts failing, the damage shows up as late orders and doubtful counts. Hexagon traced the client's issues to their causes, repaired them carefully and delivered the ERP work on sound ground. If your operations depend on an older database that nobody on your team wants to touch, talk to us before the next failure forces the question.
Talk to us about your projectRelated services: ERP development · database services · custom software development
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