{"id":15575,"date":"2023-10-10T07:35:50","date_gmt":"2023-10-10T07:35:50","guid":{"rendered":"https:\/\/www.mrpeasy.com\/blog\/?p=15575"},"modified":"2023-12-06T13:37:40","modified_gmt":"2023-12-06T13:37:40","slug":"7-real-life-manufacturing-challenges","status":"publish","type":"post","link":"https:\/\/www.mrpeasy.com\/blog\/7-real-life-manufacturing-challenges\/","title":{"rendered":"7 Real-Life Manufacturing Challenges Resolved with MRP Software"},"content":{"rendered":"\n<p>Managing the processes of a small manufacturing company is an enormous task rife with issues to resolve. Here are seven real-life manufacturing challenges that MRP software helps you overcome.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"576\" src=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2023\/10\/7-manufacturing-challenges-1024x576.jpg\" alt=\"7-manufacturing-challenges\" class=\"wp-image-15576\" srcset=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2023\/10\/7-manufacturing-challenges-1024x576.jpg 1024w, https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2023\/10\/7-manufacturing-challenges-300x169.jpg 300w, https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2023\/10\/7-manufacturing-challenges-768x432.jpg 768w, https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2023\/10\/7-manufacturing-challenges-1536x864.jpg 1536w, https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2023\/10\/7-manufacturing-challenges.jpg 1920w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<!--more-->\n\n\n\n<p><em>You can also listen to this article:<\/em><\/p>\n\n\n\n<iframe title=\"7 Real-Life Manufacturing Challenges Resolved with MRP Software\" allowtransparency=\"true\" height=\"150\" width=\"100%\" style=\"border: none; min-width: min(100%, 430px);height:150px;\" scrolling=\"no\" data-name=\"pb-iframe-player\" src=\"https:\/\/www.podbean.com\/player-v2\/?i=54939-151a983-pb&#038;from=pb6admin&#038;share=1&#038;download=1&#038;rtl=0&#038;fonts=Arial&#038;skin=1&#038;font-color=&#038;logo_link=episode_page&#038;btn-skin=3\" loading=\"lazy\"><\/iframe>\n\n\n\n<div id=\"ez-toc-container\" class=\"ez-toc-v2_0_80 counter-hierarchy ez-toc-counter ez-toc-custom ez-toc-container-direction\">\n<div class=\"ez-toc-title-container\">\n<p class=\"ez-toc-title\" style=\"cursor:inherit\">Table of Contents<\/p>\n<span class=\"ez-toc-title-toggle\"><a href=\"#\" class=\"ez-toc-pull-right ez-toc-btn ez-toc-btn-xs ez-toc-btn-default ez-toc-toggle\" aria-label=\"Toggle Table of Content\"><span class=\"ez-toc-js-icon-con\"><span class=\"\"><span class=\"eztoc-hide\" style=\"display:none;\">Toggle<\/span><span class=\"ez-toc-icon-toggle-span\"><svg style=\"fill: #343333;color:#343333\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" class=\"list-377408\" width=\"20px\" height=\"20px\" viewBox=\"0 0 24 24\" fill=\"none\"><path d=\"M6 6H4v2h2V6zm14 0H8v2h12V6zM4 11h2v2H4v-2zm16 0H8v2h12v-2zM4 16h2v2H4v-2zm16 0H8v2h12v-2z\" fill=\"currentColor\"><\/path><\/svg><svg style=\"fill: #343333;color:#343333\" class=\"arrow-unsorted-368013\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"10px\" height=\"10px\" viewBox=\"0 0 24 24\" version=\"1.2\" baseProfile=\"tiny\"><path d=\"M18.2 9.3l-6.2-6.3-6.2 6.3c-.2.2-.3.4-.3.7s.1.5.3.7c.2.2.4.3.7.3h11c.3 0 .5-.1.7-.3.2-.2.3-.5.3-.7s-.1-.5-.3-.7zM5.8 14.7l6.2 6.3 6.2-6.3c.2-.2.3-.5.3-.7s-.1-.5-.3-.7c-.2-.2-.4-.3-.7-.3h-11c-.3 0-.5.1-.7.3-.2.2-.3.5-.3.7s.1.5.3.7z\"\/><\/svg><\/span><\/span><\/span><\/a><\/span><\/div>\n<nav><ul class='ez-toc-list ez-toc-list-level-1 ' ><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-1\" href=\"https:\/\/www.mrpeasy.com\/blog\/7-real-life-manufacturing-challenges\/#Intro\" >Intro<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-2\" href=\"https:\/\/www.mrpeasy.com\/blog\/7-real-life-manufacturing-challenges\/#Stockouts_and_overstocking\" >Stockouts and overstocking<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-3\" href=\"https:\/\/www.mrpeasy.com\/blog\/7-real-life-manufacturing-challenges\/#Data_getting_lost\" >Data getting lost<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-4\" href=\"https:\/\/www.mrpeasy.com\/blog\/7-real-life-manufacturing-challenges\/#High_administrative_overhead\" >High administrative overhead<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-5\" href=\"https:\/\/www.mrpeasy.com\/blog\/7-real-life-manufacturing-challenges\/#Traceability_regulations\" >Traceability regulations<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-6\" href=\"https:\/\/www.mrpeasy.com\/blog\/7-real-life-manufacturing-challenges\/#Managing_complex_BOMs\" >Managing complex BOMs<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-7\" href=\"https:\/\/www.mrpeasy.com\/blog\/7-real-life-manufacturing-challenges\/#Remote_collaboration\" >Remote collaboration<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-8\" href=\"https:\/\/www.mrpeasy.com\/blog\/7-real-life-manufacturing-challenges\/#Scaling_up\" >Scaling up<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-9\" href=\"https:\/\/www.mrpeasy.com\/blog\/7-real-life-manufacturing-challenges\/#Conclusion\" >Conclusion<\/a><\/li><\/ul><\/nav><\/div>\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Intro\"><\/span>Intro<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>Manufacturing is hard work. And managing it is even harder. This is especially true for small manufacturers that need to wear multiple hats every single day, making sure that production schedules are accurate and adhered to, that materials reach the shop floor at the right time, that orders are put in and processed in due time, that product quality is up to standard, that costs are kept in check, and so forth.<\/p>\n\n\n\n<p>It\u2019s tough. And it\u2019s made tougher by increasingly heavy regulations, constant supply chain disruptions, and labor capacity fluctuations endemic to our age. But when the going gets tough, the tough get smarter.<\/p>\n\n\n\n<p>A growing number of small manufacturers are turning to software to alleviate their various day-to-day pains. Here are seven real-life manufacturing challenges that genuine companies from various industries have overcome with the help of MRP software.<\/p>\n\n\n<div class=\"banner-v2\">\n    <p class=\"banner-v2__desc\">Easily overcome your manufacturing troubles with MRPeasy<\/p>\n    <a class=\"banner-v2__link\" href=\"https:\/\/mrpeasy.com\/sign-up\/\" target=\"_blank\" data-ga-event=\"blog_signup_banner_blue\">Try for free<\/a>\n<\/div>\t\t<style>.banner-v2 {\n    float: right;\n    display: flex;\n    flex-direction: column;\n    justify-content: center;\n    align-items: center;\n    padding: 40px 32px;\n    gap: 16px;\n    width: 356px;\n    height: 205px;\n    background: linear-gradient(199.68deg, #6084E5 13.17%, #5FA7DD 82.1%);\n    border-radius: 4px;\n    margin-left: 12px;\n    margin-bottom: 12px;\n    margin-top: 15px;\n}\n\n@media (max-width: 767.98px) {\n    .banner-v2 {\n         width: 100%;\n         height: 173px;\n         margin-bottom: 0;\n         margin-left: 0;\n    }\n}\n\n.single__content p.banner-v2__desc {\n    margin: 0 !important;\n}\n\np.banner-v2__desc {\n    width: 292px;\n    font-style: normal;\n    font-weight: 700;\n    font-size: 22px;\n    line-height: 29px !important;\n    text-align: center;\n    color: #FFFFFF;\n    margin: 0 !important;\n    order: 0 !important;\n}\n\n.single__content a.banner-v2__link {\n    color: #FFFFFF !important;\n}\n\n.single__content a.banner-v2__link:hover {\n    color: #003557 !important;\n}\n\na.banner-v2__link {\n    display: flex;\n    justify-content: center;\n    align-items: center;\n    width: 181px;\n    height: 51px;\n    padding: 18px 0;\n    border-radius: 4px;\n    background: #003557;\n    font-weight: 700;\n    font-size: 16px;\n    color: #FFFFFF !important;\n    text-decoration: none !important;\n    order: 1 !important;\n}\n\n.banner-v2__link:hover {\n    background: white;\n    color: #003557 !important;\n}<\/style>\n\t\t\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Stockouts_and_overstocking\"><\/span>Stockouts and overstocking<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>One of the biggest issues that MRP software tackles is <a href=\"https:\/\/www.mrpeasy.com\/blog\/5-tips-for-making-material-planning-more-effective\/\" target=\"_blank\" rel=\"noreferrer noopener\">material planning<\/a>. The need to find a balance between too little and too much stock is very acute in small manufacturing companies as each unit represents tied-up cash that could be put to good use elsewhere. MRP software is made to accurately determine material requirements, ensure timely stock replenishments, and facilitate demand planning, allowing companies to optimize their inventory.<\/p>\n\n\n\n<p>\u201cUsing our previous system, it took me a day to understand what parts we needed to order and when,\u201d says Matt Zimmerman, Founder and CEO of US sonar systems manufacturing company FarSounder. \u201cWith MRPeasy, it takes less than an hour.\u201d<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Data_getting_lost\"><\/span>Data getting lost<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>Data is key to making good business decisions. But managing business information in spreadsheets (or even worse, physical archives) is unsustainable in the long run as finding the correct piece of data becomes increasingly difficult as the company grows. Within an <a href=\"https:\/\/mrpeasy.com\/mrp-system\/\" target=\"_blank\" rel=\"noreferrer noopener\">MRP system<\/a>, however, your data is organized in a way that enables easy navigation and quick search.&nbsp;<\/p>\n\n\n\n<p>\u201cWe now have all the information in one place \u2013 we can see the part, when it\u2019s due, what the costs are, everything. All you need to find is just one click away, which saves us a huge amount of time, and we have eliminated the horrendous paper trail we previously had,\u201d details Lee Brien, Director of Operations at UK precision engineering company <a href=\"https:\/\/www.mrpeasy.com\/blog\/case-study-mrpeasy-a-wrate-engineering\/\" target=\"_blank\" rel=\"noreferrer noopener\">A Wrate Engineering<\/a>.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"High_administrative_overhead\"><\/span>High administrative overhead<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>Although necessary, it seems counterproductive to hire additional administrative staff if you could put the same resources into growing the manufacturing side of the business. The level of automation MRP software creates, however, allows companies to significantly reduce administrative tasks, especially those involving data entry and analysis.<\/p>\n\n\n\n<p>Javed Bashir, Production Director at international textile manufacturing company <a href=\"https:\/\/www.mrpeasy.com\/blog\/success-story-ba-quilting\/\" target=\"_blank\" rel=\"noreferrer noopener\">B&amp;A Quilting<\/a> confirms this: \u201cWe are about eight times the size we were in 2017 but have barely doubled the administrative side of things. MRPeasy really has helped us immensely.\u201d<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Traceability_regulations\"><\/span>Traceability regulations<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>Being able to track the flow of goods throughout the value chain brings substantial benefits to any company, but especially to those working in heavily regulated industries. Achieving <a href=\"https:\/\/www.mrpeasy.com\/blog\/traceability\/\" target=\"_blank\" rel=\"noreferrer noopener\">traceability-related regulatory compliance<\/a> can be a daunting challenge but it is made effortless by MRP software.<\/p>\n\n\n\n<p>\u201cI had a target to install MRPeasy and become ISO 9001 approved within 6 months. After 6 months of using the system, SGS (an industry-leading certification company) came in to undertake the certification audit and we passed without a single non-conformance. On the report, SGS also commented on how good MRPeasy was with traceability,\u201d states Paul Watson, founder of <a href=\"https:\/\/www.mrpeasy.com\/blog\/success-story-mpw-precision\/\" target=\"_blank\" rel=\"noreferrer noopener\">MPW Precision<\/a>.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Managing_complex_BOMs\"><\/span>Managing complex BOMs<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>Although the <a href=\"https:\/\/www.mrpeasy.com\/blog\/bill-of-materials\/\" target=\"_blank\" rel=\"noreferrer noopener\">bill of materials<\/a> functionality is the core of every proper production planning software, many MRP systems do not support complex, multi-level BOMs or BOMs with parameters. Therefore, if you need to manage and plan the manufacturing of intricate products with lots of subassemblies, make sure to find a solution that accommodates that.<\/p>\n\n\n\n<p>Ralph Jones, Director at <a href=\"https:\/\/www.mrpeasy.com\/blog\/success-story-britannia-2000-holdings\/\" target=\"_blank\" rel=\"noreferrer noopener\">Britannia 2000 Holdings<\/a>, knows a thing or two about complex products: \u201cMRPeasy is brilliant, it\u2019s enabled us to build up BOMs for all our products. We have BOMs for each individually printed circuit board and for each sub- and final assembly. It works a treat. One of our mission computers has a BOM of 15-20 pages.\u201d<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Remote_collaboration\"><\/span>Remote collaboration<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>For businesses operating from a single facility, the COVID-19 pandemic illustrated the need to be able to work and collaborate remotely. For many companies, however, interregional or international collaboration is an everyday reality regardless of natural disasters or public health crises. In manufacturing companies, this is enabled by implementing cloud-based MRP software.<\/p>\n\n\n\n<p>\u201cWe had staff in two locations in the US, plus the procurement department in Taiwan, therefore we needed a system that could be accessed from anywhere,\u201d says Dennis Lan, Supply Chain Director at lighting systems manufacturer <a href=\"https:\/\/www.mrpeasy.com\/blog\/success-story-anthem-one\/\" target=\"_blank\" rel=\"noreferrer noopener\">Anthem One<\/a>. \u201cBefore implementing MRPeasy, it was hard to tell which part was where. Now, we know exactly.\u201d<\/p>\n\n\n<div class=\"banner-v1\">\n    <div class=\"banner__text\">\n        <div class=\"banner-v1__title\">Your business deserves effective software<\/div>\n        <div class=\"banner-v1__desc\">MRPeasy users report a 54% average improvement in the overall performance of their company and a 42% increase in on-time deliveries.<\/div>\n        <div><a class=\"banner-v1__link\" href=\"https:\/\/mrpeasy.com\/sign-up\/\" target=\"_blank\" data-ga-event=\"blog_signup_banner_white\">Try for free<\/a><\/div>\n    <\/div>\n    <div class=\"banner__img\">\n        <img decoding=\"async\" src=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/themes\/mrpeasy\/assets\/images\/banner.svg\" alt=\"banner\">\n    <\/div>\n<\/div>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Scaling_up\"><\/span>Scaling up<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>Although growth is generally a positive thing, scaling up operations can be very tough for managers. While spreadsheets cannot accommodate a growing business for too long, even some MRP systems can become an impediment if their functionality is not up to par with what serious manufacturers need. That is why considering your future requirements is as important as considering current ones when choosing a software solution.<\/p>\n\n\n\n<p>Paola Dyboski, founder of <a href=\"https:\/\/www.mrpeasy.com\/blog\/success-story-dr-zigs\/\" target=\"_blank\" rel=\"noreferrer noopener\">Dr Zigs<\/a> bubble toy company, feels confident about further growth: \u201cThere is definitely more functionality to roll out and I am sure we will implement [the MRP system] further as the need arises and our use case and abilities grow. Because MRPeasy grows with you, you can decide as you go, how much you want to implement and then do it in stages.\u201d<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Conclusion\"><\/span>Conclusion<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>The challenges that plague small manufacturers are real and demanding. However, with MRP software as a trusted ally, these challenges become just tiny hurdles on the path to manufacturing success. As the manufacturing landscape evolves, one thing remains constant: MRP software is here to make it smarter, more efficient, and more profitable.<\/p>\n\n\n\n<p><em>You may also like: <a href=\"https:\/\/www.mrpeasy.com\/blog\/success-story-frozen-garden\/\" target=\"_blank\" rel=\"noreferrer noopener\">Frozen Food Manufacturer Raises Efficiency by 400%<\/a><\/em><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Managing the processes of a small manufacturing company is an enormous task rife with issues to resolve. Here are seven real-life manufacturing challenges that MRP software helps you overcome.<\/p>\n","protected":false},"author":7,"featured_media":15576,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[94],"tags":[],"class_list":["post-15575","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-tips"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v26.7 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>7 Real-Life Manufacturing Challenges Resolved with MRP Software<\/title>\n<meta name=\"description\" content=\"Managing the processes of a small manufacturing company is an enormous task. 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