Blog
Insights on production scheduling, lean manufacturing, and manufacturing software from 35+ years of industry experience.
Featured Guides
Lean-MRP Hybrid: How to Combine Pull Scheduling with MRP for Long-Lead Materials
Lean and MRP appear to conflict—but most lean shops still need MRP for long-lead purchased materials. Here's how to combine pull scheduling and MRP at the right decoupling points.
MRP Data Accuracy: The #1 Reason MRP Implementations Fail (And How to Fix It)
Poor data quality kills MRP before it starts. Learn the three data pillars, how to hit the 98% inventory accuracy target, and a practical implementation checklist.
MRP Time Fences: Frozen, Slushy, and Open Planning Zones Explained
Time fences stop MRP nervousness by protecting your near-term schedule. Learn how to set frozen, slushy, and open zones—with real examples for job shops and flow shops.
Pegging in MRP: How to Trace Customer Orders All the Way to Raw Materials
Pegging lets you trace any MRP planned order back to its demand source—and forward from any supply shortage to the customer orders at risk. Here's how to use it.
Best MRP Software for Small Manufacturers in 2026
Compare the best MRP software for small manufacturers in 2026. Detailed reviews of pricing, features, ease of use, and implementation timelines to help you choose the right MRP system.
Bill of Materials (BOM) Guide: Types, Structure & Best Practices
Complete guide to bills of materials in manufacturing. Learn BOM types, single vs multi-level structures, BOM accuracy best practices, and how BOMs drive MRP and production planning.
Closed-Loop MRP: How Feedback Transforms Material Planning
Learn how closed-loop MRP connects planning with shop floor execution. Understand the feedback mechanisms, capacity validation, and continuous improvement cycle that make MRP effective.
18 Common MRP Mistakes (And How to Fix Them)
Avoid the most common MRP mistakes that cause stockouts, excess inventory, and planning failures. Practical fixes for data accuracy, parameter settings, process discipline, and system configuration issues.
DDMRP (Demand-Driven MRP): How It Works & When to Use It
Understand Demand-Driven MRP (DDMRP) and how it improves on traditional MRP with strategic decoupling points, dynamic buffers, and demand-driven execution. Learn when DDMRP fits your operation.
Dependent vs Independent Demand: The Key to Manufacturing Planning
Understand the difference between dependent and independent demand in manufacturing. Learn why this distinction drives MRP logic, inventory strategies, and material planning approaches.
MRP for Custom Manufacturing: Planning When Every Order Is Different
Learn how to apply MRP in custom and engineer-to-order manufacturing. Covers configurable BOMs, preliminary material planning, long-lead procurement, and integrating MRP with finite capacity scheduling.
MRP Implementation Checklist: 7 Phases to Go-Live Success
Complete MRP implementation checklist covering data preparation, system configuration, testing, training, go-live, and post-implementation optimization. Avoid the common pitfalls that derail MRP projects.