Sailing Manufacturer Puts Out Fires for Good with MRP Software

When Judy and David Blumhorst acquired Cruising Design International, it was meant as their low-stress retirement business. However, without proper production management, putting out fires became the daily norm. Thankfully, the duo decided to implement MRP software early on.

An iconic brand, now a family-run operation

Cruising Design International (CDI) is a California-based sailing equipment company with a history spanning over 40 years. CDI makes furlers, devices used in sailboats that simplify rolling up and deploying sails. It sells primarily through dealers and chandleries, a network spanning around 100 companies throughout North America. It also supplies spare parts directly to end customers while dropshipping complete furlers to buyers.

Since its inception in the 1970s, CDI has changed hands several times. In late 2023, it was purchased by Judy and David Blumhorst, a husband‑and‑wife team who manage all aspects of operations themselves. Judy, who has been selling CDI’s products since the 1990s, handles most machining, while David focuses on assembly. Together, they manage planning, purchasing, production, shipping, and customer relationships. It’s a few‑hundred‑thousand‑dollar operation run by two people.

The bottleneck: seasonal demand, long lead times, and zero foresight

CDI operates in a seasonal industry, with most sales occurring between March and June. During this time, there is very little room for supply errors, which means that accurate demand forecasting and inventory control are paramount. Each furler consists of about 50 parts, many with long lead times, that are arranged in multi-level bills of materials (BOMs). A shortage of even one component can halt production for the entire line.

That’s exactly what happened in their first season as owners. “We didn’t notice that we needed one particular part and ordered it too late. By the start of the season, it hadn’t arrived. That cost us the whole season of sales for that particular furler,” says David.

CDI’s existing solution, a basic inventory system, could track and manage stock on hand but offered no meaningful forecasting or lead time estimation, and almost entirely lacked production planning features. It failed to cascade demand through BOMs, didn’t have automatic reorder alerts, and couldn’t provide the visibility needed to anticipate shortages. David realized that what CDI needed wasn’t just inventory tracking but full on material requirements planning.

Big-box ERP wasn’t an option

Recognizing the need for MRP software was one thing. Finding the right system was another. Many enterprise systems are priced and designed for much larger operations. “There is no way for a great many SMEs to go the SAP or similar route with six to seven-figure implementation costs. And small businesses make up a large segment of the industry—tens of thousands of companies in North America alone,” David explains.

Looking through app marketplaces, the Blumhorsts explored several options to satisfy their intricate mix of requirements. They needed capable inventory tracking with forecasting capabilities, compatibility with QuickBooks Online and ShipStation, sales order management, and shipping capabilities. All at a price point a two-person shop could justify. But most fell short of balancing features with affordability.

MRPeasy emerged as a contender when it repeatedly appeared in searches and marketplace recommendations. The app’s solid user reviews and practical feature set put it on the couple’s shortlist. “MRPeasy promised a price-to-capability ratio that seemed just right for us. It either included all the features we needed or offered seamless integrations for them,” Judy remarks.

Though initially cautious, the Blumhorsts found no comparable alternative offering such a compelling balance of price and performance, and decided to move forward with MRPeasy. As it would quickly turn out, their decision paid off in spades.

Go-live in weeks, then refine workflows

CDI went live with MRPeasy on May 1, 2024. David prepped and migrated historical data without issues, and within a few weeks, the couple were running sales orders, reserving stock, launching manufacturing orders (MOs), and placing orders through the system.

While there was a learning curve—particularly in forecasting and reporting—the couple soon found their rhythm. “You need to learn how to “think in a software,” David explains. “Once we understood MRPeasy’s logic, day-to-day management got easy.”

The Blumhorsts also engaged a consultant from Business Solution Providers, one of MRPeasy’s trusted long-time implementation partners, to refine their processes further. This helped CDI adopt best practices and uncover more efficient ways to use some of the software’s features. The consulting spend was in the 5-10k ballpark, which the Blumhorsts consider money well spent.

Streamlined forecasting, order management, and fewer fires

With reliable forecasting and demand propagating through multi-level BOMs, part shortages are no longer a constant threat, and the couple can enter high season without worrying about availability. Judy even jokes that her blood pressure has dropped since she no longer has to worry about late parts. “We’ve gotten out of the firefighting mode thanks to MRPeasy. It’s way more cost and time-efficient, and we have much fewer rejects.”

Order management and documentation workflows have also greatly improved. Orders get confirmed, inventory is booked, MOs are scheduled, POs go to vendors, and shipping flows through ShipStation, all without manual effort. David especially values the inventory levels chart in MRPeasy’s item list. If a count looks off, he can trace the timeline, spot a double or missed receipt issue, and fix it fast. “There is no way the two of us could run this size of company without MRPeasy,” he says.

The change is visible in their day-to-day life, too. Instead of constantly double-checking spreadsheets or wondering what is missing, the Blumhorsts can concentrate on running and even enjoying their business. David says, “We have a tiny company with some sophisticated material handling needs like multi-level BOMs, long lead times, and intricate vendor relationships. MRPeasy meets those needs perfectly.“

Advice to SMEs: step away from the spreadsheets

The Blumhorsts offer straightforward advice to other SMEs: “Excel is horrible to try to run a business with. It’s flexible but fragile. You can set up sophisticated formulas and even do some light programming on it, but if you don’t protect it right, the whole thing is way too easy to break.”

More intricate spreadsheet programs are available, like Smartsheet, which links sheets and layers reports, but, as David puts it, “I still can’t imagine doing proper demand projection or requirements planning with it. Manufacturing software purpose-built for the task will outperform it every time.”

Today, MRPeasy gives CDI forward visibility. David can project demand eight to twelve months out, and if something’s off, he assumes it’s his process, not the system. “That’s how much trust we’ve come to place in MRPeasy. It gives us the visibility and traceability that Excel or any other software in this price range simply couldn’t. MRPeasy makes running our business easy and helps us pretend that we’re retired people.”

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