Manufacturing
500 MRP Exceptions a Day. Planners Now Act on 30.
A discrete manufacturing company running SAP ECC with 4 production plants was drowning in MRP exception noise. Planners couldn't distinguish critical stock-out risks from low-priority alerts. Verporta MRP AI changed that in 2 weeks.
Industry
Discrete Manufacturing
SAP System
SAP ECC 6.0 EhP8
Daily MRP Exceptions
400–600 per MRP run
Planning Team
6 MRP planners
The Problem
Exception noise was hiding the real risks
What was happening
- ▸MRP running daily (MDBT) producing 400–600 exceptions per plant per run
- ▸All exceptions displayed at equal priority – critical stock-outs buried under low-priority reschedule messages
- ▸Planners spending first 3 hours of every day sorting exceptions before any action taken
- ▸Exception 25 (new planned orders) and Exception 10 (reschedule-in) mixed together with no business context
- ▸No visibility into which exceptions were linked to open customer orders or promised delivery dates
Business impact
- ✕2 stock-out events in 6 months – both caused by critical exceptions going unnoticed in the noise
- ✕Customer SLA compliance declining – on-time delivery at 87%, target was 96%
- ✕Planner overtime increasing – team regularly working late to clear exception queues
- ✕Senior planner attrition risk – highly skilled planners frustrated by repetitive manual sorting
The Solution
Verporta MRP AI – deployed in 2 weeks
Verporta connected to SAP ECC via standard RFC, reading MRP results from MD04, MMBE, ME2M, and MD61 after each MDBT run. No add-on installation required.
MRP data connected
MD04, MMBE, ME2M, MD61 tables read via RFC after each MDBT run. Results available within 5 minutes of MRP completion.
Business impact scoring
Each exception scored 0–100 on 3 factors: stock-out risk (days of supply vs lead time), customer impact (open SO quantity and delivery date), supplier reliability (historical OTD rate and open PO status).
Priority classification
HIGH (score 70+), MEDIUM (40–69), LOW (below 40). Planners see HIGH exceptions first – typically 25–35 per day vs 500+ raw.
Exception dashboard
Planners access a prioritised view showing: exception type, material, plant, priority score, linked customer orders, suggested action. Drill-down to SAP MD04 transaction pre-filled.
Verporta modules used
Results – 30 days post deployment
Numbers that changed the business
94%
Reduction in exceptions requiring planner review
3x
Planner productivity increase
0
Stock-out events in 60 days post-deployment
97.2%
On-time delivery rate (up from 87%)
2 hrs
Time planners now spend on exceptions (down from 6+)
Technical Details
Exception Types
10 (reschedule-in), 15 (reschedule-out), 20 (cancel), 25 (new planned order), 30 (past due firmed order)
SAP Tables
MD04, MMBE, ME2M, MD61, MCBE, VBAK
SAP Version
ECC 6.0 EhP8, MRP type PD
Deployment
On-premise Docker, plant server
See Verporta Inside Your SAP Environment
30-minute live demo. We connect to a sample SAP system and show IDoc AI working in real-time. No slides. No pitch deck. Just the product.