What are the main limitations of MRP systems in modern manufacturing?

While MRP systems excel at planning material requirements and generating purchase/production orders, they often lack real-time visibility into shop-floor execution. They don’t monitor actual production progress, enforce quality checks, capture variances during build, manage complex product configurations, or provide traceability for every unit. In high-mix, low-volume, or configure-to-order environments, MRP alone can lead to discrepancies between planned and actual performance, hidden rework, quality issues, and inefficient operations—issues that require a complementary execution layer.