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It is estimated that over 100 MRPII systems are available in the market, many of them are mature enough to meet most of the users’ requirements. Manufacturing companies worldwide have attempted to implement these MRPII systems, however, failure is often experienced by many companies. Very often this failure is due to managerial rather than technical issues. In order to overcome this difficulty, this paper proposes an approach to integrate Total Quality Management into the MRPII implementation. In order to guide the implementation, a detail road map is developed which incorporates TQM into the implementation. This road map is designed using a hierarchical analysis technique called Integrated DEFinition Method (IDEF), a systematic manufacturing management and integration modeling tool. The proposed approach is illustrated using a PCB factory and the results indicated successful MRPII implementation to achieve higher productivity and delivery performance.

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