Zero-Data-Loss Migration Runbook

Manufacturing Cutover: Migrating Shop Floor BOMs from Excel to Katana

A practical roadmap to transition between tools smoothly—avoiding duplicate data, missing records, or downtime for your team.

⏱ Estimated: 2 Weeks • Complexity: Moderate

4-Phase Technical Execution Checklist

Phase 01 Days 1 - 5

BOM & Material SKU Standardisation

Objectives:
  • De-duplicate raw material names and assign strict SKU identifiers
  • Standardize units of measure (e.g. converting grams, kilograms, and ounces to unified base units)
Technical Execution Steps:
  1. Export existing spreadsheets into Katana CSV import templates
  2. Structure multi-level Bill of Materials with accurate scrap rate multipliers
  3. Import supplier price lists and default purchase lead times
Validation Gate: All recipes pass Katana automated import validation checks with zero circular sub-assembly loops.
Phase 02 Days 6 - 10

Physical Stock Count & Go-Live Cutover

Objectives:
  • Conduct comprehensive weekend physical stock count
  • Upload initial stock balance into Katana as the live baseline
  • Train shop floor staff on tablet barcode scanning and manufacturing order completion
Technical Execution Steps:
  1. Lock Excel spreadsheets to prevent modification
  2. Upload physical stock take CSV with location bin assignments
  3. Generate active Manufacturing Orders for work-in-progress (WIP) batches
  4. Deploy Katana Shop Floor app on tablets across production stations
Validation Gate: Physical inventory matches Katana stock figures within 1% margin of error.
Total Cost of Ownership (TCO) Baseline

Manufacturing Cutover: Migrating Shop Floor BOMs from Excel to Katana: 3-Year Benchmark (30 Seats)

Comparing legacy monolithic enterprise suites against a connected modular stack with native automation.

Architecture Strategy Base License (Annual) Add-ons & API Overages Year 1 Total Year 3 Total Cost Variance
Legacy All-In-One Enterprise Suite $96,000 $14,400 $110,400 $331,200 Baseline
Connected Modular Stack (Native Sync) $43,500 $0 (Native Webhooks) $43,500 $130,500 Save ~61% ($200,700)

*Data based on verified enterprise rate cards and standard API quota tiers. Modular setups eliminate third-party middleware subscriptions and custom ETL maintenance costs.