Use Case · Manufacturing IT

What if your ERP crashes during morning dispatch?

When the server your entire production floor depends on hits 95% CPU, the difference between 4 minutes and 2 hours is whether someone was watching.

💻
The Scenario
A manufacturing unit runs Tally ERP for billing, dispatch, and inventory. A runaway background process causes the application server CPU to spike during peak morning hours.
ERP Server — CPU Usage 96%
10:30 AM — ERP server CPU spikes to 95%. Tally begins to slow.
↓ Two timelines branch from this moment
Without Reliability360
R3
With Reliability360
10:45 AM
Tally freezes for all users
CPU reaches 100%. The ERP becomes completely unresponsive. Billing, dispatch, and inventory — all halted.
10:48 AM
Production floor cannot process dispatch
3 trucks are waiting. Gate passes cannot be generated. Drivers start calling the office.
10:52 AM
IT person finally reached
Staff walked to the IT room. The technician was in a meeting. Multiple calls needed to get through.
11:30 AM
Root cause still unclear
IT checking logs manually. No monitoring tool to show what caused the spike. Server restarted as a guess.
12:30 PM
System restored — 2 hours later
Tally is back. 3 trucks delayed. One customer calls to complain. The incident goes undocumented.
10:28 AM
Early warning at 80% CPU
Before Tally is impacted, the monitoring system detects the spike — 17 minutes before the system would freeze.
10:29 AM
WhatsApp to IT person — with context
"ERP Server: CPU at 82% and rising. Top process: batch_export.exe. Check process table immediately."
10:31 AM
Root cause identified and killed
IT connects remotely. Identifies a scheduled batch export that ran at the wrong time. Process terminated in 2 minutes.
10:32 AM
CPU normal. ERP unaffected.
Tally continues working without a single user noticing anything unusual. Dispatch proceeds on schedule.
10:33 AM
Incident auto-logged and closed
CPU spike, alert, response, and resolution time — all documented with timestamps for the weekly operational report.
4 min
Time to resolution with Reliability360 vs. 2 hours without it. 3 trucks on time. Zero customer complaints. Root cause fixed, not just rebooted.
Without Reliability360 — Impact
⏱2 hours of ERP downtime during peak dispatch hours
🚛3 delivery trucks delayed — customer SLA breached
📵Root cause never identified — will happen again
📋Incident undocumented — no learning, no prevention
With Reliability360 — Outcome
✓Zero downtime — caught 17 minutes before impact
✓All deliveries on time — customers unaware of anything
✓Root cause fixed — batch schedule corrected
✓Incident auto-logged — appears in weekly operations report

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See also: Use Case 1 — Cold storage goes out of range at 11pm →