Industry
Discrete Manufacturing
Region
United States
Modules
Manufacturing, MRP, Inventory, Shop Floor
The challenge
- On-time delivery had fallen below 80%.
- MRP suggested constant expediting; planners had stopped trusting it.
- Shop floor was running on whiteboards instead of Sage X3.
- Inventory levels were rising despite stockouts on critical components.
Our approach
Master data clean room
Sat with engineering and planning to clean BOMs, routings, and lead times for the top 20% of items driving 80% of revenue.
Planning policy redesign
Replaced flat reorder-point logic with ABC-based planning policies and demand-variability-driven safety stock.
Shop floor adoption
Redesigned shop floor screens for the way operators actually work. Eliminated the whiteboards through better daily release procedures.
Planning KPI dashboard
Daily and weekly planning KPIs visible to planners, supervisors, and the COO.
Outcomes
- On-time delivery improved to 95%+
- Inventory reduced by approximately 18% while service improved
- Planners returned to running MRP daily as their primary tool
- Whiteboards retired in favor of Sage X3 work order execution