Production planning and turnkey MRP system

When production is small, the plan is kept in the head of the workshop manager and a couple of tables. But as soon as there is a flow of orders, this scheme begins to malfunction: either the machine is idle without work, then in the midst of a large order the raw materials run out, then the client is given a deadline at random and then it is missed. Production planning and an MRP system are needed precisely in order to see in advance what and when to produce, how much materials to purchase and whether the workshop capacity is enough. In this article, we will explain in simple terms what MRP is, why planning “by eye” and in Excel sooner or later fails, and what planning of production and material requirements inside Taska gives - where order, production and purchasing live in the same circuit.

What is the cost of production without a plan?

The lack of normal planning hits money from several sides at once, and the owner feels it, but can rarely point the finger. Downtime: work centers stand idle because orders are piled up haphazardly, and bottlenecks emerge only when deadlines are already running out. Lack of raw materials: the manager accepts the order without knowing the balance, and the shortage is discovered when the machine is ready to cut - the output stops, the client is waiting. Missing deadlines: a date is promised at random, without reference to the actual workload of the workshop and the delivery time of materials, and then they lose trust and repeat orders. And the opposite extreme is freezing money: to be on the safe side, they buy raw materials with a reserve “just in case,” and working capital lies like a dead weight in the warehouse instead of working. Each of these problems individually seems like a small thing, but together they are the very drain of profit that is difficult to notice in the general bustle.

What is MRP in simple words

MRP (Material Requirements Planning) is planning of material requirements. To put it simply: you tell the system what needs to be produced and in what quantity and by what time, and it itself calculates how much and what kind of raw materials will be needed for this, what of this is already in stock, and what and when needs to be purchased in addition. The calculation is based on specifications (BOM) - the exact composition of each product: how many and what materials are used per unit. The following logic is simple, but it takes a long time to calculate it by hand and it’s easy to make mistakes:

• A production plan is taken - how many products and by what date should be made for orders
• According to BOM specifications, the total requirement for raw materials and components for the entire volume is considered
• The current balances in the warehouse and what is already on the way are subtracted from the requirement
• The remainder turns into a purchasing task - what, how much and by when to order to the supplier
• At the same time, the work center load is checked to see if the workshop can produce the volume on time
• Bottlenecks and shortages are visible in advance, and not at the moment when production has already stopped

Production planning in Taska

In Taska, planning is collected into one work circuit, and is not scattered across files and employees’ heads. You create a production plan directly for orders from the sales department: a transaction in the funnel generates a production order, and the manager does not need to duplicate anything in Excel and send it to the shop floor in words. According to BOM specifications, the system automatically calculates the need for raw materials and materials for the entire plan, checks it with the rest of the raw material warehouse and immediately shows what and how much is missing - this becomes a purchasing task with specific deadlines. The load on work centers is clearly visible: it is clear which area is overloaded, where a bottleneck occurs, and whether it is realistic to meet the deadline promised to the client. The link order → production → purchase works in one system and one currency UZS: the order reserves and writes off materials, the shortage is visible before the start of production, and not after the fact. The manager can see at any time at what stage the order is at, whether there are enough raw materials and whether the workshop fits into the plan - without calling the foremen and checking three different tables.

Why is it better than Excel and head

Planning in the head works exactly as long as there are few orders and one person holds them: he goes on vacation or quits - and the entire production logic goes with him. Excel lives a little longer, but it has its own ceilings: the balances in the table differ from what is in the warehouse, the need for materials is recalculated manually after each new order, the formulas break down, and the table cannot really show the workload of the workshop and the deadlines. The main thing is that Excel is not connected either to sales orders, or to the warehouse, or to purchases, so the data has to be transferred manually, and at each such junction, applications are lost and errors accumulate. The system recalculates demand and load automatically in seconds, maintains uniform balances for the warehouse and workshop, and links order, production and purchasing into one flow. This is suitable for industries with recipes and shift work - furniture and sewing shops, food production, metalworking, packaging and assembly. We implement turnkey: we analyze your stages, operations and specifications, set up a plan, warehouse and reports for a real model, transfer balances and items, connect Telegram for orders and notifications and exchange with 1C and MoySklad. We do a basic launch as an MVP in 14 days, and choose a format - ownership with a one-time payment or subscription.

We will plan your production

Leave a request for a free consultation. We will analyze your products, specifications and workload of the workshop, show with a specific example how Taska will calculate the need for raw materials for the production plan and connect the order, production and purchase into one circuit, and we will tell you where it is more profitable to start implementation so that the workshop stops being idle and missing deadlines.