Affordable MRP for Smaller Manufacturer

Sleepmaster LTD is a AUD $50M manufacturer with operations in Australia and China. Their situation mirrors thousands of small and mid-size manufacturers worldwide: an outdated MRP system with no effective scheduling capability, a new international facility with no system at all, and the need for an affordable solution that could deliver results immediately.

They found it in Resource Manager from User Solutions — and deployed it first in their Chinese startup operation to get the new facility running quickly.

Read the full Sleepmaster success story.

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The Challenge: Two Countries, Zero Effective Scheduling

Sleepmaster faced two distinct scheduling challenges simultaneously.

Australia: An outdated MRP system with no effective scheduling ability and cumbersome product costing. The system existed but was not meeting their needs.

China: A brand-new facility with no MRP system at all, staffed by people with little modern manufacturing experience. Everything needed to be built from scratch.

The problems Sleepmaster needed to solve:

• Scheduling that allows quick changes in very dynamic demand situations
• Quick and easy product costing
• Materials requirements planning
• BOMs and routes that could be built quickly "on the run"

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The Solution: Phased, Affordable, International

Sleepmaster evaluated multiple systems — both local Australian solutions and global platforms. Most were "far more expensive and comprehensive" than what they needed. Resource Manager won on five criteria:

1. Easy and intuitive to use — no complex training required
2. Usable in sections within days — materials planning first, then costing, then scheduling
3. Low cost — affordable for a $50M organization without enterprise budgets
4. Easily configurable and flexible — adapts to their specific workflows
5. Good remote support — via Skype, phone, and GoToMeeting with fast turnaround

The Phased Approach

Sleepmaster's implementation approach is a model for other small manufacturers:

Phase 1: Materials planning — Get visibility into what materials are needed, when, and how much. This delivers immediate value for purchasing.

Phase 2: Costing — Understand the true cost of each product based on BOMs, routings, and resource consumption. This supports pricing decisions and profitability analysis.

Phase 3: Scheduling — Add finite capacity scheduling to optimize production flow and provide accurate delivery dates.

Each phase delivered value independently while building toward a complete manufacturing management system. This is the key advantage: "A whole system can be built up while it is generating value."

China First

Sleepmaster strategically deployed Resource Manager in China first — the facility with no existing systems and limited manufacturing experience. This was the highest-impact starting point because it transformed a greenfield operation with zero planning capability into a structured manufacturing environment with materials planning, costing, and scheduling.

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Why Affordability Changes the Equation

The Enterprise Software Tax

Most MRP and scheduling systems are priced for large enterprises. The license costs, implementation fees, and ongoing maintenance create a "software tax" that small manufacturers cannot justify. Sleepmaster explicitly noted that most alternatives were "far more expensive and comprehensive" — meaning they were paying for capabilities they would never use.

Speed to Value Matters More Than Feature Depth

For a small manufacturer, the ability to start generating value within days matters more than having every conceivable feature. Sleepmaster started using materials planning immediately, then layered in costing and scheduling over time. This approach generates ROI from day one rather than waiting months for a comprehensive implementation to complete.

International Operations Need Simple Tools

When deploying across countries — especially in facilities with limited manufacturing experience — simplicity is critical. Complex enterprise systems that require specialized training and dedicated IT support are impractical for international startup operations. Resource Manager's simplicity and remote support capability made international deployment feasible.

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Lessons for Small and International Manufacturers

Phase your implementation. Do not try to implement everything at once. Start with the area that delivers the most immediate value — usually materials planning or scheduling — and expand from there.

Evaluate total cost, not just license cost. Consider implementation time, training requirements, ongoing maintenance, and support costs. A "cheaper" system that takes three times as long to implement may cost more overall.

Deploy to your biggest pain point first. Sleepmaster deployed to China first because that was where the need was greatest. Focus your implementation where it will have the most impact.

Simplicity is a feature. For small manufacturers and international operations, simplicity of use is more valuable than comprehensive feature lists. If your team cannot use the system easily, features do not matter.

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Frequently Asked Questions

Why did Sleepmaster choose Resource Manager over larger MRP systems?

Sleepmaster evaluated multiple local and global systems but chose Resource Manager because it was easy and intuitive, could be used in sections within days, was low cost, easily configurable, and offered good remote support. The biggest benefit was simplicity of operation and speed at generating results.

Can Resource Manager work for international manufacturing operations?

Yes. Sleepmaster used Resource Manager across operations in both Australia and China. They deployed it first in China — where staff had little modern manufacturing experience — to quickly get the new facility up and running with materials planning, costing, and scheduling.

How does Resource Manager handle a phased implementation approach?

Resource Manager can be implemented in sections without requiring the whole system at once. Sleepmaster started with materials planning, then added costing, then scheduling — each delivering value independently while building toward a complete system.

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Affordable MRP for Your Operation

If enterprise MRP systems are too expensive and complex for your operation, Sleepmaster's experience proves there is an affordable, effective alternative. Request a free demo and see how Resource Manager DB delivers MRP and scheduling at a price point that works.

Read the full Sleepmaster success story and explore all scheduling success stories.