When your ERP vendor tells you their own scheduling module is not enough for your operation and recommends a third-party scheduling add-on — that says something powerful about the complexity of production scheduling and the limitations of ERP-based scheduling.
That is exactly what happened with Plastilite Corporation of Omaha, Nebraska. Their ERP vendor, Fourth Shift (from Softbrands, Inc.), recommended Resource Manager DB from User Solutions because Fourth Shift's own scheduling module could not handle Plastilite's injection molding complexity.
The result: a 5-day implementation that delivered a fully optimized, finite capacity schedule with complete ERP integration.
Read the full Plastilite success story.
The Challenge: Scheduling Beyond ERP Capabilities
Plastilite Corporation provides insulated and protective packaging solutions, shipping everything from Omaha Steaks to pies to vaccines and biological materials. To support growth and improve manufacturing competitiveness, they decided to implement a new ERP system.
Fourth Shift was the frontrunner for accounting and inventory needs, but the scheduling module was not flexible or advanced enough for Plastilite's production scheduling. The core problem: managing many injection molding machines, each with different tool configurations holding different combinations of molds for a variety of products. This level of manufacturing complexity was "far too complex for ERP's basic infinite capacity scheduling system."
Jon Ehly, Plastilite's Chief Financial Officer, explained that Fourth Shift itself recommended Resource Manager DB as an add-on to handle the advanced production planning and scheduling requirements.
The Solution: Monday to Friday, Zero to Optimized
What happened next is one of the most impressive implementation timelines in manufacturing software history.
Jon Ehly described it directly: "We made the decision to go live with both systems in the same week — a process I would not necessarily recommend for the faint of heart. We had started the ERP Training and Implementation months ago then called User Solutions to come on site to help us with the scheduling module. They arrived on Monday and by Friday we had a complete optimized schedule generated with full integration with our ERP System."
What Was Accomplished in 5 Days
Within one week, User Solutions accomplished:
- Breaking down key scheduling data from Plastilite's production environment
- Entering routings with alternate workcenters for production flexibility
- Managing variable chest and tool sizes across the injection molding fleet
- Importing open orders from the Fourth Shift ERP system
- Generating an optimized, finite capacity constrained schedule
- Exporting updated dates back to synchronize with MRP and inventory
User Solutions also proactively added functionality to select optimal workcenters with corresponding chests and molds — without additional charges. This is the kind of responsive customization that makes the difference between a scheduling tool that sort of works and one that fits your operation precisely.
Why ERP Vendors Recommend RMDB
The Plastilite case highlights a pattern that repeats across the manufacturing industry: ERP vendors recognize the limitations of their own scheduling modules.
ERP Does What ERP Does Well
ERP systems excel at managing accounting, inventory, purchasing, and materials planning. These are transactional systems designed to track what has happened and what materials are needed. They were not designed for the combinatorial optimization problem that production scheduling represents.
Scheduling Is a Different Problem
Production scheduling requires finite capacity modeling, resource constraint management, what-if scenario analysis, and dynamic rescheduling. These capabilities require specialized algorithms and user interfaces that are fundamentally different from ERP transaction processing. The best ERP vendors — like Fourth Shift in this case — recognize this and recommend specialized tools.
Integration, Not Replacement
The Plastilite implementation demonstrates that adding a scheduling add-on to an existing ERP is straightforward. Orders flow from ERP into RMDB, the scheduling engine optimizes against finite capacity, and updated dates flow back to synchronize MRP and inventory. Both systems do what they do best.
Lessons for Manufacturers Evaluating ERP Scheduling
Ask your ERP vendor about scheduling limitations. If they claim their scheduling module handles everything, ask specifically about finite capacity constraints, what-if scenarios, and complex resource configurations. The honest vendors — like Fourth Shift — will acknowledge the gaps.
Plan for both ERP and scheduling simultaneously. Plastilite implemented both in the same week. While Jon Ehly noted this was "not for the faint of heart," the approach ensured that scheduling was not an afterthought. If you are implementing or upgrading ERP, evaluate scheduling add-ons at the same time.
Expect rapid implementation. If your ERP data is clean and accessible, a scheduling add-on implementation can happen in days, not months. The Plastilite 5-day timeline is achievable for manufacturers with well-organized production data.
Look for proactive customization. User Solutions added functionality for optimal workcenter and mold selection without additional charges. This kind of responsiveness distinguishes vendors who understand manufacturing from those who just sell software.
Frequently Asked Questions
Why did Fourth Shift ERP recommend Resource Manager DB?
Fourth Shift recognized that their ERP system's basic infinite capacity scheduling could not handle Plastilite's complex injection molding scheduling needs — managing multiple machines with different tool configurations and mold combinations. They recommended Resource Manager DB as an advanced scheduling add-on.
How fast was the Plastilite scheduling implementation?
User Solutions arrived on Monday and by Friday Plastilite had a complete optimized schedule with full ERP integration. The team accomplished data breakdown, routing entry, variable management, order importing, schedule generation, and ERP date synchronization in one week.
Can scheduling software handle injection molding complexity?
Yes. Plastilite's injection molding operation required managing many machines with different tool configurations holding different combinations of molds for various products. Resource Manager DB handled this complexity by selecting optimal workcenters with corresponding chests and molds automatically.
Get the Scheduling Your ERP Cannot Provide
If your ERP scheduling module is not delivering the finite capacity scheduling you need, you are not alone. Even ERP vendors recommend Resource Manager DB for advanced scheduling.
Ready for a scheduling add-on that works? Request a free demo and we will show you what RMDB adds to your ERP.
Read the full Plastilite success story and explore all scheduling success stories.
Frequently Asked Questions
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User Solutions Team
Manufacturing Software Experts
User Solutions has been developing production planning and scheduling software for manufacturers since 1991. Our team combines 35+ years of manufacturing software expertise with deep industry knowledge to help factories optimize their operations.
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