Discrete ManufacturingUnited StatesManufacturing & Distribution
Manufacturing MRP Optimization in Sage X3
MRP tuning, BOM/routing cleanup, shop floor execution, planning KPIs.
ManufacturingMRPInventoryShop Floor
At a glance
Industry
Discrete Manufacturing
Company type
US mid-market discrete manufacturer
ERP focus
Sage X3 MRP, BOM/routing, shop floor, planning KPIs
Main challenge
MRP output distrusted; shop floor bypassed Sage X3 with whiteboards.
PRH services
Master-data clean room · Planning policy redesign · Shop floor adoption · Planning KPI dashboard
Key result
OTD to 95%+ with planners running MRP daily.
Region
United States
Operational 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
Business challenge
An operation running at scale without the systems to match it.
The organization ran multiple sites with continuous inventory movement — a volume and complexity that had outgrown its manual processes.
- 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.
Solution
A warehouse execution platform built end-to-end in Sage X3.
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.
Platform
Built on Sage X3.
Manufacturing
MRP
Inventory
Shop Floor
More case studies
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- Food & Beverage Manufacturing & DistributionReal-Time Warehouse Automation Supporting 800+ Pallets Daily
- Food & Beverage DistributionCaribbean Food & Beverage Multi-Company Sage X3 Implementation
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