6. MRP

Material Resource Planning

Copyright 2011 John Wiley & Sons, Inc.

Material Requirements Planning

MRP Inputs and OutputsInputsMaster production scheduleProduct structure fileItem master file

OutputsPlanned order releasesWork ordersPurchase ordersRescheduling notices

Master Production ScheduleDrives MRP process with a schedule of finished productsQuantities represent production not demandQuantities may consist of a combination of customer orders and demand forecastsQuantities represent what needs to be produced, not what can be producedQuantities represent end items that may or may not be finished products

Master Production Schedule

Product Structure

Copyright 2011 John Wiley & Sons, Inc.

Product Structure Tree

Multilevel Indented BOM

Item Master File

MRP ProcessesExploding the bill of materialNetting out the inventoryNettingthe process of subtracting on-hand quantities and scheduled receipts from gross requirements to produce net requirementsLot sizingdetermining the quantities in which items are usually made or purchasedTime-phasing requirements

MRP Matrix

MRP

MRP

MRP - 1

MRP - 2

MRP - 3

MRP - 4

MRP - 5

MRP - 6

MRP - 7

ITEM: PRESSBOARDLLC: 1PERIODLOT SIZE: MIN 100LT: 112345Gross RequirementsScheduled ReceiptsProjected on Hand150Net RequirementsPlanned Order ReceiptsPlanned Order ReleasesITEM: CLIPBOARDLLC: 0PERIODLOT SIZE: L4LLT: 112345Planned Order Releases100100100ITEM: LAPDESKLLC: 0PERIODLOT SIZE: MULT 50LT: 112345Planned Order Releases5050MRP - 8

ITEM: PRESSBOARDLLC: 1PERIODLOT SIZE: MIN 100LT: 112345Gross Requirements 1001002001000Scheduled ReceiptsProjected on Hand150Net RequirementsPlanned Order ReceiptsPlanned Order ReleasesITEM: CLIPBOARDLLC: 0PERIODLOT SIZE: L4LLT: 112345Planned Order Releases100100100ITEM: LAPDESKLLC: 0PERIODLOT SIZE: MULT 50LT: 112345Planned Order Releases5050MRP 9x1x1x1x2x2

ITEM: PRESSBOARDLLC: 0PERIODLOT SIZE: MIN 100LT: 112345Gross Requirements 1001002001000Scheduled ReceiptsProjected on Hand150505000Net Requirements50150100Planned Order Receipts100150100Planned Order Releases100150100ITEM: CLIPBOARDLLC: 0PERIODLOT SIZE: L4LLT: 112345Planned Order Releases100100100ITEM: LAPDESKLLC: 0PERIODLOT SIZE: MULT 50LT: 112345Planned Order Releases5050MRP 10x1x1x1x2x2

MRP - 11

Copyright 2011 John Wiley & Sons, Inc.15-*

Copyright 2011 John Wiley & Sons, Inc.

Planned Order Report

MRP Action Report

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