Cut inventory by 35% while achieving 99.5% availability.

To be successful in today’s “instant gratification” marketplace, it’s crucial to always have the right products and materials on hand to fulfill customer demand. Demand Driven Material Requirements Planning (DDMRP) is an innovative production planning and inventory control system that unites the best of Lean Manufacturing, Theory of Constraints (TOC), and Six Sigma principles to ensure you’ll always have optimal inventory levels — never carry too much and never run out. This eliminates the cost of excess inventory and lost sales due to out-of-stocks.

icon Never make too much of anything again!

Never make too much of anything again!

DDMRP’s re-supply recommendations are based on actual consumption — you only make what customers are buying. This ensures that you won’t have a surplus of products and that your supply won’t run out.

icon End expedited shipping and overtime.

End expedited shipping and overtime.

Costly overtime and expedited shipments are eliminated with DDMRP because what is needed to meet customer demand is always available. This also provides you with a lead-time edge that enables you to beat out competitors.

icon Bring Scheduling and Visiblity to Any ERP.

Bring Scheduling and Visiblity to Any ERP.

DDMRP simplifies material requirements planning and removes reactive drama from day-to-day inventory management in your existing ERP solution.

icon Deliver on time.

Deliver on time.

Having what customers want on hand significantly improves on-time delivery, which helps create loyal customers while reducing time-pressure related workplace tension.

Reacting to changing customer demand in real time is the new way to manufacture.
icon Carry Less Inventory and Never Run Out

Carry Less Inventory and Never Run Out

No one is in the business of carrying too much inventory. It’s requires costly space, handling, and can go obsolete quickly. DDMRP allows you to reduce inventory, yet always meet your customer or production commitments.

icon Free Up Money

Free Up Money

As DDMRP aligns your production and purchasing with the real needs of your customers, you will end the common practice of overstocking. Less goods in inventory means more money available for strategic initiatives.

icon Build Customer Trust

Build Customer Trust

At the heart of DDMRP is its constant look at what and when the customer is buying. You no longer need to guess at this and try to forecast what will happen. Using DDMRP will increase your fill rates, which in turn increases customer satisfaction and loyalty.

icon Strengthen Your Supply Chain

Strengthen Your Supply Chain

Your relationships with your vendors and customers will be stronger when you are providing accurate information that can be trusted. You will no longer be placing orders only to have to come back and change them up or down.

icon Synchronize Your Sub Assemblies

Synchronize Your Sub Assemblies

You can’t finish a product unless all the parts are there. DDMRP ensures that all parts are completed when needed. Using “Elastic Due Dates”, DDMRP continually adjusts interrelated work order due dates as manufacturing or customer conditions change.

icon Stay in Front of Production Problems

Stay in Front of Production Problems

Production stops when material shortages occur. Just like a customer, the production floor demands that material be available on time. DDMRP, balances both customer and production demand in real time and ensures that material is stocked for both.

Why our customers refer us.
Video Poster

We implemented Protected Flow Manufacturing (PFM) in 2017 for its Demand Driven Material Requirements Planning (DDMRP) functionality and the surrounding features of LillyWorks. PFM suited our Enterprise Resource Planning (ERP) needs. PFM is a great all-around fit for our company. Our biggest concern was our raw material supply chain management and as a mature startup, we are aggressively growing which means things change for us rapidly. The DDMRP component and the way that PFM handles the order points and buffers in real-time, on the fly, is exactly what we need. We import our customer forecasts and utilize the historical demand which resizes our buffers automatically; order points are magically moved as needed and safety stock is handled perfectly by PFM every time without issues. PFM supports our rapidly growing company and is worth it! My advice to any manufacturer looking at PFM would be to get educated on DDMRP, compare it to traditional MRP, and once you have determined it is the right fit for your company, go with LillyWorks PFM.

Thomas Roberts, CEO
Rational Packaging
Video Poster

We now manage 70% of our materials (by $ value) for manufacturing and customer service under DDMRP. We started our pilot program in April and have been fully implemented since Mid-May. Our average lead time to our customer has been reduced 11 days to 2.2 days, while also realizing a 3% reduction in inventory investment.

Tim Hendrickson, EVP of Operations
Wipaire Inc.
Video Poster

Running out of inventory items at the worst possible time – a common result of executing a plan based on forecasting– is eliminated by DDMRP, Mr. Lilly said. These DDMRP features, are embedded in our ERP system or can work in tandem with any existing ERP system already installed, make sure the manufacturer never runs out of critical inventory items.

Mark Lilly, President & CEO
LillyWorks
Video Poster

With DDMRP we have nearly eliminated expedites. Our inventory is down by 25% in four months and we have no Stocks Outs.

Fernando Plaza, Manager
IFAM
We deliver results that drive business.
99.5%
fill Rate accuracy that can be achieved
with DDMRP
20%
overstock and obsolete eliminated by DDMRP
15%
reduction in raw material and in process
stock required for production
Consumption Based <span>Ordering</span>

Consumption Based Ordering

Manufacturers traditionally try to forecast what future consumption will be. Inaccurate forecasting can therefore instruct manufacturing plants to over or under produce what is really needed.  DDMRP  dynamically looks at the changes in demand and adjusts the supply orders accordingly.  This results in just the right amount of inventory for both product items and customer end items.

Buffers Inventory Levels Up & Down the <span>Supply Chain</span>

Buffers Inventory Levels Up & Down the Supply Chain

DDMRP understands the dependencies of inventory at every level of manufacturing. Raw materials supply material to sub assemblies. Sub assemblies are needed for higher assemblies and customer end items. The levels of stock from raw material through upper level assemblies and finished goods need to be optimized so that no stockouts occur.  Today’s MRP systems address this by creating static material plans and then issuing “exceptions” to planners who have to manually make adjustments.  DDMRP makes these adjustments automatically as consumption conditions change.

Improved <span>On-Time Delivery</span>

Improved On-Time Delivery

The only way to deliver on time is to make sure that you have all of the material to make your product.  Stockouts at any level of the supply chain or manufacturing process can leave you with no time to make the product for delivery.  By monitoring all material demand and supply in real time, DDMRP anticipates potential material problems and adjusts inventory before problems arise.

Who can benefit from DDMRP?
Automotive Manufacturing
Energy Manufacturing
Furniture & Fixtures
Industrial Manufacturing
Medical Device Manufacturing
Process Manufacturing
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Automotive Manufacturing

Automotive Manufacturing

As a manufacturer in the specialty vehicle industry, such as boats or emergency vehicles, you need a solution that can quickly respond to unique product configurations and accurately budget and manage actual costs associated with these jobs or projects. Infor ERP is it!
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Highlights
  • Configuration management
  • Serial and lot control
  • Design and engineering
  • Capacity planning & scheduling (Lean, TOC, JIT)
  • Actual costing
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Energy Manufacturing

Energy Manufacturing

Synergy has a track record of implementing the right software, deploying efficient business processes, and developing the right metrics. This provides you with the insight and visibility you need into business operations and drives desired behaviors.
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Optimize People, Processes, & Technology.
  • Strengthen Your Supply Chain
  • Sophisticated Project Management
  • Connect Service Efforts to Operations
  • Localization & Financial Accounting Visibility
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Furniture & Fixtures

Furniture & Fixtures

Today's customers demand that furniture and fixture manufacturers offer new product lines and custom options for existing products on demand. We can help you build speed and flexibility into your engineering and production processes so you can meet expectations.
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Highlights
  • Industry Expert Partners
  • Increase Quote Win Rate
  • Improve Planning & Scheduling
  • Cut Operational Costs
  • Shorten Product Development Lifecycles
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Industrial Manufacturing

Industrial Manufacturing

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Highlights
  • End-to-end customer relationship, sales, purchasing, performance, and financial management
  • Estimating with multiple quantity breaks
  • Integrated capacity planning (Lean, TOC, JIT) with unlimited "what-if" scenarios
  • Material planning with real-time visibility of demand and supply
  • Cost control (actual, average, standard)
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Medical Device Manufacturing

Medical Device Manufacturing

Synergy's Continuous Improvement teams have helped medical device manufacturers to increase productivity both in the office and on the shop floor. Our ERP products enable employees to complete assigned tasks faster and make more products without increasing costs.
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Highlights
  • End-to-end customer relationship, sales, purchasing, performance, and financial management
  • Estimating with multiple quantity breaks
  • Integrated capacity planning (Lean, TOC, JIT) with unlimited "what-if" scenarios
  • Material planning with real-time visibility of demand and supply
  • Cost control (actual, average, standard)
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Process Manufacturing

Process Manufacturing

As a food, beverage, chemical, or life science manufacturer, you have specific requirements when it comes to your manufacturing operations. Infor CloudSuite Process makes it easy to adjust formulas based on exacting manufacturing specifications and to monitor and respond to the evolving regulatory environment.
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Highlights
  • Flexible Formula Management
  • Stay On Top of Quality Requirements & Regulations
  • Build a Better Batch
  • Lot Recall
  • Process Workbench