MRP ran at midnight. By 8 AM the picture has already changed — and nobody knows.
Standard ERP MRP runs overnight as a batch process. By the time the planner opens the MRP report in the morning, the demand picture has already shifted — new sales orders have arrived, a batch has been put on quality hold, a supplier has confirmed a delay. The MRP output the planner is working from is 8–12 hours old before the first decision of the day is made.
The gap between the MRP snapshot and reality is where shortages hide. A material that looked covered at midnight may be short by 9 AM — because a new confirmed order consumed the projected stock, or because an inbound PO was rescheduled overnight. The planner finds out when the line stops, not when the gap opens.
MRP is a calculation, not a report — and calculations can run continuously. HublerX maintains a live material requirements position by reconciling confirmed sales orders, open work orders, current stock levels, and inbound PO commitments in real time. When any input changes — a new order arrives, a batch is held, a PO is rescheduled — the material position updates immediately and any new gap is surfaced to the planner before it becomes a stoppage.
Live workflow view
The step-by-step sequence
- 1
Confirmed orders pulled from ERP in real time
HublerX reads confirmed sales orders from the ERP continuously — not as a scheduled batch. Every new order, every order revision, and every cancellation updates the demand picture immediately.
Continuous · on every order event - 2
Live stock position reconciled
Current stock levels — raw materials, WIP, and finished goods — are read from the ERP and WMS in real time. Batches on quality hold are excluded from available stock automatically. Stock consumed by running work orders is decremented as production progresses.
Continuous · on every stock event - 3
Inbound PO commitments tracked
Open purchase orders and their confirmed delivery dates are read from the ERP. Where a supplier has updated an ETA — via EDI, portal, or manual confirmation — the revised date is reflected in the material position immediately.
Continuous · on every PO event - 4
Material gaps identified and ranked
When the live MRP calculation identifies a gap — projected stock falling below the requirement for a confirmed work order — HublerX flags it immediately, ranked by production impact and days to breach. Gaps are visible to the planner the moment they open, not the next morning.
On gap detection · real time - 5
Planner and procurement alerted simultaneously
When a gap is detected, the production planner and the responsible buyer receive the alert at the same moment — with the material, the quantity short, the work order at risk, and the latest inbound PO status. No sequential phone chain. No gap between detection and response.
Immediately on gap flag - 6
Gap resolved and position updated
Once the gap is resolved — a PO is expedited, an alternate material is approved, or a work order is rescheduled — HublerX updates the material position and closes the alert. The live MRP position reflects the resolution immediately.
On gap resolution
Results are directional. Outcomes vary by ERP integration depth, supplier data quality, and production schedule complexity.
See how live MRP works in your operation
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