Window and door manufacturers face a unique challenge in today’s fast-paced market: they must manage a variety of production methods while meeting customer-specific requirements. Whether producing standard stock items or fully customized architectural pieces, these companies need to adapt to fluctuating demands without sacrificing quality or delivery timelines by adopting a mixed-mode manufacturing strategy.
To thrive in this environment, many window and door manufacturers turn to Enterprise Resource Planning (ERP) systems. The best ERP systems support mixed-mode manufacturing, a production strategy that blends make-to-stock (MTS), make-to-order (MTO), and sometimes engineer-to-order (ETO) methods. Read on to learn how the right ERP system can help mixed-mode production run more smoothly and efficiently, allowing more time to work with window and door customers.
What Is an ERP System?
An Enterprise Resource Planning (ERP) system is a comprehensive software solution that integrates and automates core business functions into a unified database and interface. An ERP serves as a digital backbone for manufacturers, allowing them to manage workflows from quote to cash with precision and insight.
A modern ERP system eliminates silos, provides real-time data visibility, and facilitates cross-functional collaboration. In manufacturing, especially for companies that juggle different production types, ERP becomes essential for scheduling, material planning, cost control, and customer service.
Dedicated to high-volume, mixed-mode window and door manufacturers, Frontier ERP is the industry choice for custom manufacturing.
What Is Mixed-Mode Manufacturing?
Mixed-mode manufacturing refers to the simultaneous use of multiple production strategies within a single facility or company. This could mean producing standard windows or doors in batches (MTS), crafting unique configurations based on customer selections (MTO), or even designing custom units from scratch (ETO).
For door and window companies, mixed-mode production is the norm. For example, a company might produce a standard line of storm doors for retail chains. At the same time, they are also fulfilling dealer orders for custom wood doors with decorative glass inserts. Managing these workflows requires flexible production planning, advanced scheduling, and real-time material availability, all of which can be achieved through the best ERP systems.
Best ERP Features for Multi-Mode Manufacturers
Here are the top ERP processes and features that drive success for door and window companies:
1. Product Configuration and CPQ (Configure-Price-Quote)
Buyers often want options: different materials, colors, dimensions, hardware, finishing, and energy efficiency levels. ERP systems with built-in product configurator tools enable manufacturers to manage this complexity.
- Parametric product configurators allow users to define rules and dimensions so that customers or sales teams can create feasible product variants.
- CPQ software ensures that quotes are fast and accurate, pricing reflects real costs, and production-ready orders flow directly into the ERP.
This is essential for supporting make-to-order and engineer-to-order processes without slowing down production or introducing errors.
2. Advanced Bill of Materials (BOM) and Routing Management
Mixed-mode manufacturers need BOMs that can to both standard and custom builds. ERP systems must support:
- Multi-level BOMs for subassemblies like sashes, frames, or insulating glass units.
- Dynamic BOMs that adjust based on product configuration.
- Routing flexibility to support different machines, work centers, or subcontractors depending on order type.
These capabilities ensure efficient material planning and labor scheduling across all production modes.
3. Production Scheduling and Shop Floor Control
When manufacturing using a mixed-mode approach, it is imperative to balance stock orders with urgent custom jobs. The best ERP systems offer:
- Finite capacity scheduling that accounts for machine time, labor availability, and material constraints.
- Batch production tools that give production managers more control over batch runs.
- Shop floor data collection or MES integration to track work in progress, labor hours, and scrap in real time.
With these features, manufacturers can optimize throughput, reduce changeover time, and ensure on-time delivery for both high-volume and one-off orders.
4. Inventory and Materials Management
Mixed-mode production creates complexity in inventory, including raw materials, components, and finished goods. The best ERP systems help by:
- Managing raw material forecasting and procurement based on sales, production orders, and historical trends.
- Enabling barcode scanning and lot/bin tracking for real-time inventory visibility.
- Supporting just-in-time (JIT) or safety stock strategies depending on the production mode.
This ensures that every window or door, whether stock or custom, has the right components at the right time.
5. Integrated Quality Control
Maintaining consistent quality is critical in window and door manufacturing, especially when switching between different order types. ERP systems should support:
- In-process quality checks and inspection points based on item or production type.
- Nonconformance tracking, corrective actions, and audit trails.
- Full traceability of components, assemblies, and processes for compliance and warranty support.
Quality assurance must be baked into every step, from purchasing to shipping.
6. Field Service, Warranty, and CRM Integration
Many window and door manufacturers also handle installation, maintenance, or field repairs. ERP systems with field service management and customer relationship management (CRM) tools provide:
- Service dispatch and scheduling.
- Warranty tracking is linked to specific product serial numbers or batches.
- Dealer support portals for tracking order status, service issues, and parts availability.
These features not only support after-sales service but also improve long-term customer satisfaction.
7. Financials, Reporting, and Analytics
To manage multiple production modes effectively, window and door manufacturers need deep visibility into costs and profitability. The best ERP systems provide robust analytics and reporting features like:
- Standard cost vs. actual cost analysis.
- Profitability by order, product, customer, or dealer.
- Cash flow, budgeting, and variance reports that tie financial performance back to operations.
Real-time dashboards and customizable reports help leaders make fast, informed decisions in a mixed-mode environment.
Why Mixed-Mode Manufacturers Choose Frontier ERP
Friedman Corporation has over 40 years of experience serving window and door manufacturers with complex production requirements. Our Frontier ERP system is purpose-built to support mixed-mode manufacturing across make-to-stock, make-to-order, and engineer-to-order processes.
Frontier’s strengths include:
- A robust product configurator with parametric logic for complex assemblies like double-hung windows, sliding patio doors, or custom-sized storm doors.
- Built-in CPQ tools for dealer networks and customers to create accurate quotes and 3D visualization.
- Flexible BOM and routing capabilities that automatically adapt to the chosen configuration.
- Powerful scheduling and shop floor tracking that match labor and machine capacity with real-time demand.
- Seamless data integration between purchasing, inventory, sales, engineering, and finance to improve communication and eliminate manual errors.
We also support eWebServices, DataBroker, and eQuote Dealer for connecting online portals, including customer payment portals, directly to your ERP system.
Final Thoughts
The complexities of mixed-mode manufacturing can overwhelm some window and door companies that rely on disconnected systems or manual processes. Manufacturers gain the tools to streamline production, reduce costs, and meet customer demands across all order types by investing in the best ERP system tailored to their needs.
Frontier ERP is uniquely suited for window and door manufacturers operating in a mixed-mode environment. With decades of industry expertise and purpose-built features, Frontier ERP enables these businesses to thrive in a competitive market, supporting standard lines, custom builds, and everything in between.
To learn more about Frontier ERP, drop us your contact info or see us at AWFS® Fair 2025 in July!
