BY SOLUTION · MATERIAL REQUIREMENTS PLANNING

From demand to a dated requirement — in one calculation.

MRP compares the order against the bill of materials, on-hand stock and open orders, and calculates what is needed, how much and by when. MRP II tests that against capacity, labor and cost to make the plan feasible. The net requirement is recalculated on every stock movement.

ANATOMY OF THE CALCULATION

Three inputs, one engine, a dated output.

DemandSales orders and forecast
Bill of materialsBOM · components and quantities
Stock & open ordersreserved + critical stock
MRP engine net requirement = on-hand stock + purchase orders − (reserved quantity + critical stock)

OUTPUT · DATED NET REQUIREMENT

ProductTonnageWidthDate
Kraft Liner 90 g12.5 t183 cmMay 13
Bristol 350 g8.2 t100 cmMay 13
Laminated & glued1.4 tMay 13
Dispersion varnish0.6 tMay 13

FROM DEMAND TO A DATED REQUIREMENT

Follow the three steps in order.

winpremium · Net Requirements
Bill of materials, stock summary and net requirement table Capacity and workload control screen Handover-to-procurement screen

Derive the requirement

The order quantity is exploded through the bill of materials; each component's gross requirement is calculated, and on-hand and in-transit stock deducted. What remains is the true net requirement.

  • The bill of materials expands across levels
  • On-hand, reserved and in-transit stock are shown separately
  • Net requirements are listed with their required-by date

MRP → MRP II

From material calculation to resource planning.

MRP answers "what, how much, when". MRP II adds capacity, labor and cost to the same calculation and also answers "is this plan actually feasible?"

CORE CALCULATION

MRP

Material requirements planning — compares demand against the bill of materials and stock, and dates the net requirement.

  • Gross → net requirement calculation
  • Offsetting stock and open orders
  • Required-by and order date
  • Recalculated on every movement

RESOURCE PLANNING

MRP II

Manufacturing Resource Planning — tests the same calculation against capacity, labor and cost to make it feasible.

  • Machine and labor capacity
  • Bottlenecks and load balancing
  • Cost and cash impact
  • A feasible, approved plan

PLATFORM CAPABILITIES THAT COMPLETE MRP

A sound plan is strengthened by a sound product structure and live visibility.

NEXT SOLUTION · ENTERPRISE RESOURCE PLANNING (ERP)

The plan turns into work on one record chain.

Go to ERP

← MES · Home