Client:
A $200 million consumer packaged goods (CPG)
Challenge:
The company is a manufacturer with global sourcing operations that is dependent on precise ERP/MRP functionality for inventory planning, procurement, and fulfillment execution.
They experienced the sudden departure of its Global Sourcing Director—an essential leadership role that also carried deep operational ownership over purchasing, supplier management, and MRP system performance.
With a 3–6 month estimated timeline to recruit and onboard a replacement, the company faced immediate risk: their MRP system was delivering faulty signals, causing planners and buyers to override outputs manually, eroding trust in the system and leading to excess inventory, fulfillment delays, and team frustration.
They needed an interim solution that not only filled the leadership vacuum but also addressed the underlying system and process issues contributing to operational instability.
Strategic Objectives:
- Provide interim sourcing leadership with the ability to manage purchasing and supplier operations.
- Diagnose and correct MRP system signal errors.
- Standardize and document key purchasing and planning processes.
- Restore team trust in the system and prepare for smooth onboarding of a permanent hire.
- Reduce inventory burden while improving order fulfillment confidence.
Approach:
Waypost deployed an experienced advisor with a deep background in sourcing metals and components—aligned to the company’s materials profile—and direct experience with the client’s ERP/MRP system. This allowed for an immediate start without ramp-up friction.
The advisor took the following approach:
- Shadowed the existing purchasing and planning teams to assess both role clarity and system usage gaps.
- Conducted a deep-dive of MRP parameters and master data settings to identify misalignments and logic flaws in system-generated purchase and production signals.
- Facilitated hands-on testing and reverse-engineering of system results to trace the root causes of discrepancies.
- Defined and documented key activities, responsibilities, and expectations across sourcing, planning, and supplier management.
- Created training-ready documentation to enable a smooth transition for the incoming permanent director.
Key Steps:
- Master data audit and parameter validation
- Process documentation for purchasing, planning, and supplier coordination
- Development of an “Item Master Template” for consistent system inputs
- Redesign of the New Item Set-Up Process and Supplier Management protocols
- Alignment of job roles with performance expectations and org goals
Assessment Areas:
- ERP configuration and planning logic
- Master data integrity and completeness
- Role clarity across sourcing and planning
- Onboarding gaps and documentation readiness
- Supplier quality and data management procedures
Tools and Methodologies:
- ERP/MRP system gap analysis
- Hands-on functional testing and data tracing
- Stakeholder interviews and workflow mapping
- SOP creation and process templating
- Interim leadership coverage and team coaching
Deliverables:
- Corrected MRP signals and logic
- 3-week lead time reduction and 40% inventory requirement reduction
- Standardized item master and new item setup documentation
- Updated sourcing director role description reflecting true scope
- Documented processes for onboarding, training, and supplier governance
Conclusion:
This Waypost interim placement delivered leadership continuity and allowed for permanent operational gains. The engagement resulted in automated, reliable planning signals; reduced inventory burden; and improved purchasing team morale through clarified expectations and trust in the system.
The organization exited the engagement with durable process documentation and a stronger foundation for its next sourcing leader.
“Waypost was the first company that listened to what we needed.”— Purchasing Group