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7/29/2019 MRP Basics
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Fundamentals of MRP
Prof. Prasad Chakrabarti, CFPIM,CSCP(APICS)
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Planning and Control System
ProductionPlan
BusinessPlan
MasterProductionSchedule
Planning
Execution
MaterialRequirements
Plan
ProductionActivity Controland Purchasing
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Objectives of MRP
To determine the materials required What is required
How much is required
When it is required
To establish and maintain priorities
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Inputs to MRP Process
MPS
MRP
Planning Data
Bill ofMaterial
InventoryStatus
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Nature of Demand
Legs
206
Ends
433
Sides
711
Top
025
Hardware Kit
822
Table
100
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Description: Table
Part Number: 100
Part Number Description Quantity Required Unit of Measure
306 Wooden legs 4 EA
433 Wooden ends 2 EA711 Wooden sides 2 EA
025 Table top 1 EA
822 Hardware 1 Kit
Bill of Materials
A bill of material lists all the componentsneeded to make one assembly
Each part has a unique part number
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Bill of Materials
SingleLevel
Multilevel
Base
300
Top
025
Hardware
Kit
822
Table100
Legs
306
Leg Bolts
326
Frame
357
Base
300
Boards
031
Glue
075
Top
025
Hardware
Kit 822
Table
100
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The MRP Process
Determines What is needed
How much is needed
When to order
Involves
MPS data
Bills of material Inventory status
Planning data
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Lead Time, Exploding, and Offsetting
Lead time: The time from when an order is placed until the partis ready for use
Exploding: Multiplying the parent requirements by the usage
quantity through the product tree
Offsetting: Placing the requirements in their proper time periodsbased on lead time
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Planned Orders
Week
Item Planned Order 1 2 3 4 5
Number
B Receipt 50Release
ReceiptC Release
Receipt
D ReleaseReceipt
E Release
ReceiptF Release
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Gross and Net Requirements
Available inventory must be taken intoaccount
Net requirements = gross requirements available inventory
Example:Gross requirements 50 units
Available inventory 20 units
Net requirements 30 units
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Problem 4.3B
DC
E F LT = 1 WkLT = 1 Wk
LT = 1 WkLT = 2 Wks
LT = 1 Wk
Item Week
Number 1 3 4 5
Gross requirements 50
Projected available 20 20 20 20 20
B Net requirements 30
Planned order receipt 30
Planned order release 30
Gross requirements 30Projected available 10
C Net requirements
Planned order receipt
Planned order release
Gross requirements 30
Projected available 0 0 0
D Net requirements 30
Planned order receipt 30
Planned order release 30
Gross requirements
Projected available
E Net requirements
Planned order receipt
Planned order release
Gross requirements 20
Projected available 0
F Net requirements 20
Planned order receipt 20
Planned order release 20
2
0
0
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Problem 4.3 (Solution)B
DC
E F LT = 1 WkLT = 1 Wk
LT = 1 WkLT = 2 Wks
LT = 1 Wk
Item Week
Number 1 3 4 5
Gross requirements 50
Projected available 20 20 20 20 20 0
B Net requirements 30
Planned order receipt 30
Planned order release 30
Gross requirements 30Projected available 10 10 10 10 0
C Net requirements 20
Planned order receipt 20
Planned order release 20
Gross requirements 30
Projected available 0 0 0 0
D Net requirements 30
Planned order receipt 30
Planned order release 30
Gross requirements 20
Projected available 0
E Net requirements 20
Planned order receipt 20
Planned order release 20
Gross requirements 20
Projected available 0
F Net requirements 20
Planned order receipt 20
Planned order release 20
2