Planners run MRP and the suggestions are missing, late, too small, too large, or for the wrong items.
Why it happens
- Item planning policy set incorrectly (lot-for-lot vs. fixed vs. reorder point)
- Lead times missing or wrong
- Safety stock and minimum order quantity not configured
- BOM and routing missing or incorrect components
- Pegged demand from forecasts, sales orders, or dependent demand missing
- Site, warehouse, or status filters excluding stock
Diagnostic steps
- 1. Confirm the item plan policy
Open the item-site record and verify the planning method, lot-sizing rule, and re-order quantities.
- 2. Verify demand is visible to MRP
Run an item-level pegging or available-to-promise inquiry to see what demand MRP can actually see.
- 3. Check BOM and routing currency
An expired or inactive BOM or routing will silently break dependent demand for components.
- 4. Inspect lead time math
Sage X3 adds production, purchase, and queue/safety lead times. Off-by-one-week problems usually come from this.
- 5. Look at stock status filters
Stock in 'Quality' or 'Quarantine' status may be invisible to MRP depending on configuration.
Fixes
Reset planning parameters
Standardize planning methods across like items. Document which items are reorder-point, MRP-driven, or forecast-driven.
Refresh lead times
Recalculate purchase lead times from actual receipt history and production lead times from actual work order cycle time.
Repair master data
Inactivate obsolete BOMs and routings. Add missing components. Ensure routing operations match shop floor reality.
Tune safety stock and reorder logic
Use ABC analysis and demand variability to set safety stock instead of flat values.
Prevention
- Monthly review of MRP exception messages
- Quarterly planning parameter audit
- Master data discipline: BOM and routing changes go through engineering change control
PRH Consulting can resolve this for you
Our manufacturing practice handles issues like this regularly. Most engagements start with a short scoping call.