PRH Consulting works with discrete and process manufacturers running Sage X3 for production planning, MRP, shop floor execution, and costing. Our manufacturing architects have run plants, configured shop floor systems, and stabilized Sage X3 manufacturing modules after failed go-lives.

We focus on what the plant actually needs: BOMs that reflect how the product is built, routings that match how the equipment runs, MRP that generates actionable suggestions, and costing that the controller can defend.

Common challenges

BOMs that don't match the floor

When the BOM in Sage X3 doesn't match what the floor actually consumes, every variance is suspect and planning gets impossible.

MRP that nobody trusts

Planners stop using MRP when it generates noise. The fix is almost always in policy settings, lead times, and safety stock — not in the engine.

Shop floor data collection

Operators won't use screens designed for desk users. Backflushing, time tracking, and scrap reporting need to fit the physical workflow.

Costing that doesn't explain itself

Standard cost variances need to be analyzable. If finance can't explain a variance, the costing model is wrong for the business.

Sage X3 considerations

Discrete vs. process configuration

Sage X3 supports both, but the configuration choices differ significantly — BOM structures, routing types, lot management, and yield reporting.

Make-to-stock vs. make-to-order

Order policies, planning horizons, and product configuration must align with how the plant actually sells and produces.

Sub-contracting and external operations

Sub-contract POs, in-transit material, and consigned inventory all need explicit modeling.

Costing method

Standard with variance analysis is the most common — but average and actual have a place depending on volume and mix.

How PRH helps

BOM and routing rebuild
We work with engineering and the floor to rebuild BOMs and routings that reflect actual production.
MRP tuning
Policies, lead times, lot sizing, and safety stock tuned to produce suggestions planners actually act on.
Shop floor screen design
Operator-friendly screens for issue, receive, backflush, and time entry, designed with the people who will use them.
Costing model rebuild
Standard cost model, variance buckets, and reporting that gives finance and operations a single, defensible view.