Material Requirement Planning (MRP)

With Just-in-Time methodologies, many MTO manufacturers are faced with constantly changing blanket orders, small run repeat orders and delivery schedules that are shorter than material lead time. The Material Requirements Planning (MRP) module alleviates the stress of these situations by automating many of the processes required to keep supply and demand synchronized.

Forecast
Enter general part forecasts or specific customer/part forecasts. MRP consumes the forecast with actual orders as they are received. Lower level component requirements with long lead times are visible before the end part is released.

Master Production Schedule
The Master Production Schedule (MPS) is where you enter production forecasts for specific end parts. Perform an iterative process of entering a planned schedule, viewing the effect on your resources and then modifying the plan until you have the achieved an optimal schedule.

MRP Generation
Net change or full MRP regeneration options are available. The MRP generation process balances the demand of customer orders and forecasts with the supply of jobs. As orders and forecasts change, MRP automatically adjusts corresponding jobs so that you are always in balance. MRP even reschedules your plant for you.

Purchasing
MRP creates purchase order suggestions for all purchased parts that are needed to complete production. Lead times and vendor price breaks are used to determine when the part should be ordered and at what price.

Multi-Site
MRP can be run for all plants or individual plants within a company. Changed schedule dates roll down to all subcomponents – even those being manufactured in another plant.

Available to Promise
View running balances with the Available to Promise function. Enter a quantity and the system will find the earliest date that quantity will be available. Enter a date and see how many parts are available on that day. MPS, forecast, order and planned receipt quantities are visible to help you in your production planning tasks.

Bill of Material
MRP checks the revision level and verifies approvals before pulling in a standard bill of material and routing. For those parts which do not have a current approved revision, a job suggestion is created in the new/change order queue – eliminating the possibility of forgetting about a requirement.

Log File
A log file is available to see what changes were created by MRP.

Integration
Material Requirements Planning is fully integrated with the Order Management, Job Management, Inventory Management, Purchase Management and Multi-Site Management modules.