“Essential features got turned into paid add-ons. It felt like a bait and switch,” says Jonathan Greenwald, VP of Operations at KCL Manufacturing.
900% Cost Increase Prompts Medical Device Manufacturer to Switch ERPs
Case Study from | MRPeasy
High-stakes manufacturing, lean operations
Founded in late 2023, KCL Manufacturing is a Florida-based contract manufacturer specializing in complex electromechanical assemblies for medical devices. "We’re integrators," says Jonathan Greenwald, VP of Operations and Manufacturing. "We take preassemblies from suppliers but also internally manufacture things and then assemble, test, and calibrate everything in-house to deliver complete, regulation-compliant products to our customers."
KCL Manufacturing runs lean with four core staff and scales its production using temporary staff when necessary. It became ISO 13485 certified in record time and was nominated as Manufacturer of the Year in Florida in 2024.
Efficient manufacturing planning software was an early goal
Jonathan knew that relying on spreadsheets wouldn't cut it. "They get out of date fast, and there’s always a cycle count nightmare which inevitably leads to late and missing orders," he explains. So he made it a top priority to equip KCL Manufacturing with a proper manufacturing software solution from the outset.
In a field where compliance is non-negotiable and delays often mean lost clients, KCL’s decision to invest in manufacturing software early created a solid foundation for scaling operations. "Implementing an ERP system on day one helped us prepare for audits, track inventory, and set us up for growth," he says. "Being ISO audit-ready from the beginning was also a huge head start."
The first ERP system raised prices without warning
Initially, the company opted for a popular manufacturing software provider that seemed to meet its needs. "Our first pick did the job, for the most part."
Then they found many essential features suddenly locked behind a separate paywall. "These features were standard when we started the implementation, but then they turned them into paid add-ons, which raised our costs by 900%. When they started charging us extra for things we absolutely needed, we started looking elsewhere."
A fast, affordable alternative that just worked
Looking for new software, Jonathan and his team ran an exhaustive search and evaluated several platforms. Their requirements were clear and non-negotiable: affordability, scalability, configurability, and no need for external consultants. In the end, the SME-oriented MRPeasy checked all the boxes.
"We were skeptical at first," Jonathan admits. "But everything we were paying extra for previously came standard in MRPeasy. We did the cost-benefit analysis, and it was the clear winner."
Implementation began in early 2024. To minimize disruption, the team ran both systems in parallel for two weeks before completely switching to MRPeasy.
"MRPeasy was so easy to set up, we didn’t need any handholding," says Jonathan. "We've had maybe seven support tickets in the two years we’ve been using it."
Faster, smarter, and audit-ready
KCL Manufacturing's transition to MRPeasy brought sweeping improvements to how the company runs its operations, tracks compliance, and serves its customers. "ERP has a reputation for slowing you down," Jonathan says. "MRPeasy is the opposite—it made us faster and more organized."
One of the most immediate changes was in the inventory control area. Before, keeping track of inventory required near-constant cycle counts. Now, a single count per year suffices because stock levels remain accurate and reliable.
Forecasting and quoting processes have also been transformed. Thanks to MRPeasy's flexible cost of goods calculations, Jonathan can now generate accurate quotes for batches of any size within minutes.
Procurement is another area where MRPeasy excels. From the system's automated purchase order emails to a central hub for vendor data complete with custom categories, MRPeasy has helped accelerate communication and improved oversight across KCL Manufacturing's network of 100+ suppliers.
Finally, Jonathan reports that MRPeasy is also playing a central role in KCL's rigorous compliance efforts.
"We use MRPeasy in some unique ways," says Jonathan. "The software forms the foundation of our device history records, tying together inspection data, non-conformance reports, and floor documentation. That’s huge for our audits."
Built for growth, MRPeasy is here to stay
What started as a cost-effective replacement for an overpriced alternative has become an indispensable tool for KCL Manufacturing's day-to-day operations. The firm has plans to use MRPeasy to track overall equipment effectiveness (OEE) and expand the use of the built-in CRM in the near future.
For KCL Manufacturing, MRPeasy is a strategic asset for building high-quality, regulation-compliant products for one of the most demanding industries. "MRPeasy makes robust, value-adding ERP solutions affordable for smaller players," Jonathan concludes. "It’s a tool that needs to be set up and used correctly, but when it is, the value is exceptional."
The content & opinions in this article are the author’s and do not necessarily represent the views of ManufacturingTomorrow
MRPeasy
MRPeasy is a seriously powerful and easy to use ERP software for small manufacturers that gives you everything you need to manage your manufacturing and distribution processes. Integrating sales, procurement, inventory, production, finances, and your team, it provides you with an accurate real-time overview of your operations. MRPeasy is trusted by 2000+ small manufacturers worldwide, 700+ of which are based in the US and Canada. Our users report a 54% average improvement in the overall performance of their business and a 42% increase in on-time deliveries. Try for free, no credit card needed.
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