Manufacturing Planning System (MRP)
Production planning built around real factory constraints — BOM explosion, inventory forecasting and automated shortage alerts, backed by query optimization and caching for high-volume operations.
How it happened
Planning production on gut feeling
Production and sales orders were tracked in spreadsheets that nobody trusted. Material shortages showed up as a surprise on the shop floor, not as a warning three days earlier when there was still time to act.
Real factory math, not a generic template
Carton manufacturing has its own logic — Bill of Materials explosion, multi-stage production, and shortage windows that generic "inventory software" doesn't model correctly. A wrong forecast doesn't just cost money, it stops a production line.
Forecasting that talks before it's too late
I modeled the actual BOM structure, built inventory forecasting that accounts for lead times, and layered automated shortage alerts on top — with Redis caching so the dashboards stay fast even as order volume grows. The system now warns the planning team before a shortage happens, not after.
Less waste, more trust
Material waste dropped 35% and on-time delivery improved 50% within the first full quarter of use — and for the first time, the production floor and the planning office were looking at the same numbers.
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