MRP
General Parameters
Introduction: What is MRP?
Material Requirements Planning (MRP) is a planning and inventory control system that ensures the right material is supplied in the right quantity and at the right time for production. This module analyzes current inventory, expected orders, and production plans to determine what, how much, and when to order or produce. This guide consists of the following sections:
- General MRP Parameters: Defines the general operating rules of the planning engine.
- Product-Specific MRP Parameters: Defines special planning rules for each individual product.
- Running MRP (Starting the Planning): Explains how to start the planning process.
- Reviewing MRP Results and Creating Orders: Shows how to interpret the planning results and turn them into action.
Section 1: General MRP Parameters
This screen defines the default rules and behaviors that apply to all MRP calculations. These settings form the foundation of the planning engine. Typically, these settings are configured once and rarely changed. Screen Path: MRP Management > Run MRP > General MRP Parameters
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Core Parameters and Their Meanings:
- Horizon Duration: Specifies how far ahead MRP will plan (e.g., 90).
- Horizon Unit: Defines the unit of the horizon duration (Day, Week, Month). In the example, "Day" is selected, meaning the system will plan 90 days ahead.
- Run Type: Determines the MRP calculation method. (e.g., Net Change - only for changed items, Regenerative - full recalculation for all items).
- Past-Dated Demand Management: Determines how demands that are in the past but unfulfilled will be handled. (e.g., "Add to Today" - moves the demand to today's date).
- Planning Time Fence Days: The number of days during which the plan is frozen, i.e., closed to automatic changes. Planned orders within this period are not modified by MRP, which provides stability in short-term plans.
- Demand Time Fence Days: A time barrier that sets the last date for which new demands will be considered.
- Default Lot Sizing Rule: The default rule that defines how order quantities are determined.
- L4L (Lot for Lot): Creates an order for exactly the quantity required.
- Fixed Quantity: Always creates an order in a predetermined fixed quantity.
- Default Safety Stock Method: Determines the safety stock calculation method.
- Delay Tolerance Days: The number of days to be tolerated for supply or production delays.
- Excess Stock Warning Multiplier: A multiplier that determines when a product's stock is considered "excess".
Section 2: Product-Specific MRP Parameters
While general parameters apply to the entire system, some products may have their own specific supply, production, or stocking conditions. This screen allows you to define product-specific MRP rules within each product card. Settings made here override the general parameters. Screen Path: General Definitions > Products > Select the Relevant Product > Bill of Materials Relationships (or a similar tab)
Product-Based Settings:
The information in this area applies only to the selected product (e.g., 6754).
- Min. Production Quantity: Specifies the minimum quantity that can be produced from this product in a single run. MRP does not create a production order below this quantity.
- Quality Control Duration (Days): Specifies the additional time (in days) required for quality control processes after the product is supplied or produced. This duration affects the date on which the material becomes available.
- Goods Receipt Duration (Days): The time required for receiving and putaway operations after the material arrives at the warehouse.
- Time Per Lot: In production, refers to the setup time required for each lot.
- Periodic Order Min. Days/Duration: Used to restrict the periods in which orders can be placed (e.g., this product can only be ordered at the beginning of the week).
- Order Days: Ensures that orders for this product can only be created on specific days.
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Section 3: Running MRP (Starting the Planning)
Once all general and product-specific parameters are set, you can start the MRP calculation.
- Go to the MRP Module: It is usually located under a heading such as MRP Management or Planning in the main menu.
- Open the Run MRP Screen: This screen usually contains a "Run MRP" or "Start Planning" button to initiate planning.
- Review the Parameters: Before running, the system may ask you which planning scenario (e.g., master plan, simulation plan) you want to use.
- Run: When you click the button, the MRP engine starts running. The system;
- Aggregates all sales orders, forecasts, and independent demands (Gross Requirements).
- Calculates on-hand and in-transit inventory (Available).
- Finds Net Requirements by subtracting the available inventory from the gross requirements.
- Creates Planned Orders (for production and purchasing) by taking into account the supply and production lead times, lot sizes, and safety stock rules of the products. This process may take time depending on the amount of data. A progress bar or status notification may be displayed in the system.
Section 4: Reviewing MRP Results and Creating Orders
After the MRP run is complete, the most important step is to analyze the results and take the necessary actions. Results are usually presented as a report or an interactive table.
Result Screen
This screen usually contains information such as the following:
| Product Code | Product Name | Requirement Date | Quantity | Order Type | Suggested Order Date |
|---|---|---|---|---|---|
| PLS-SEAT03-BL | PLASTİK KOLTUK SİYAH | 20.06.2025 | 500 | Production Order | 13.06.2025 |
| HAM-CELIK-01 | ÇELİK SAC | 12.06.2025 | 1200 | Purchase Order | 09.06.2025 |
Turning Results into Action (Adding Orders)
The "Planned Orders" created by MRP are only suggestions. User approval is required to turn them into reality.
- Review the Suggestions: Carefully examine each row on the result screen. Check whether the quantities and dates are in line with your expectations.
- Select the Suggestions: Select the rows you want to convert into a real order (usually via the checkboxes at the beginning of each row).
- Create the Orders: Click a button on the screen such as "Approve Selected", "Create Order", or "Create Production Order".
- System Automation: When you click this button, the system automatically:
- Creates a new production order record in the Production Module for suggestions of type "Production Order".
- Creates a new purchase order draft or a direct order in the Purchasing Module for suggestions of type "Purchase Order". This minimizes manual data entry and provides full integration between planning and execution (production/purchasing).
Conclusion and Important Tips
- Data Integrity is the Rule: The accuracy of MRP depends entirely on the accuracy of the data you enter (bills of materials, stock levels, lead times, orders). Never forget the "Garbage In, Garbage Out" principle.
- Review Parameters Regularly: As supplier performance, production processes, or market conditions change, regularly reviewing your general and product-specific parameters keeps your plans current and realistic.
- Performance: MRP calculations can be resource-intensive. Regular maintenance of the database and optimization of queries will shorten planning times. I hope this guide helps you use the MRP module more effectively and efficiently. If you have any further questions or requests regarding database optimization, please do not hesitate to contact me.
MRP Technical Parameter Documentation
This document comprehensively explains the general and product-based parameters used in the Material Requirements Planning (MRP) module. The goal is to clarify what each parameter does so that the system can plan correctly.
1. 🔧 General MRP Parameters (MRP_Parametreleri_Genel)
Defines the fundamental planning rules that apply to all products in the MRP system. It usually contains only 1 record and determines the general behavior of the system.
| Field Name | Description |
|---|---|
| Field Name | Description |
| --------------- | -------------- |
| ParametreID | Allows only a single row to be entered into this table (default: 1). |
| UfukSuresi | Determines how much time (e.g., 90 days) MRP will plan for. |
| UfukBirimi | The unit of the planning horizon: 'Day', 'Week', 'Month'. |
| ZamanKovasiTipi | Determines how buckets will be used in reporting or scheduling (e.g., 'Daily', 'Weekly', 'Monthly'). |
| CalistirmaTipi | The run type of the MRP engine: Regenerative (all records), Net Change (only changed records). |
| GecmisTarihliTalepYonetimi | How past-dated demands are handled: Ignore, Warn, Add to First Bucket. |
| GecmisTarihliGirisYonetimi | The behavior for past-dated goods receipts is determined in the same way. |
| PlanlamaZamanCitiGun | MRP does not make changes for days before a specific date (frozen zone). |
| TalepZamanCitiGun | The time barrier for which new demands are considered valid. |
| VarsayilanLotSizingRule | The default lot sizing rule that applies to all products (L4L, FOQ, MAX, POQ). |
| VarsayilanSafetyStockMethod | The safety stock calculation method: Fixed Quantity, Daily Stock. |
| VarsayilanSafetyStockValue | The minimum stock quantity that applies to all products. |
| VarsayilanSafetyTimeDays | The default safety time (days) for all products. |
| GecikmeToleransGun | The maximum delay to be accepted in case of supply delays. |
| HizlandirmaEsikGun | The threshold to be considered when an order needs to be placed earlier than the planned date. |
| StokFazlasiUyariCarpan | If the actual stock exceeds the expected level by this multiplier, the system issues a warning. |
| KapasiteKontroluAktif | 1: Capacity control is performed. 0: Capacity control is not performed. |
| SonGuncelleme | The last update date of the parameters. |
2. 📦 Product-Based Parameters (MRP_Work_UrunParametreleri)
These are the specific parameters that determine the planning behavior for each product. The unique production, supply, and stocking conditions of products are defined in this table.
Identity and Definition Information
| Field Name | Description |
|---|---|
| MRPRunLogID | Specifies which MRP run this record belongs to. |
| UrunID | The product's unique identity in the system. |
| UrunKodu | The product code defined in the inventory or ERP system. |
| UrunAdi | The descriptive name of the product. |
| UrunTipi | Product classification such as finished product, semi-finished product, raw material. |
| BirimID | The identity of the stock unit (piece, kg, m, etc.). |
Supply and Production Lead Times
| Field Name | Description |
|---|---|
| SatinAlmaTedarikSuresiGun | Purchasing lead time (days). |
| UretimTedarikSuresiGun | Production lead time (days). |
| KaliteKontrolSuresiGun | The extra time required for quality control operations. |
| MalKabulSuresiGun | The goods receipt time of the material into the warehouse. |
Lot Sizing and Order Rules
| Field Name | Description |
|---|---|
| LotSizingRule | Lot sizing rule (L4L, FOQ, POQ, MAX). |
| FixedOrderQuantity | The fixed quantity to be ordered in each order. |
| PeriodOrderQuantityDays | Periodic order frequency (e.g., 7 = once a week). |
| MinOrderQuantity | Minimum order quantity. |
| OrderMultiple | Orders must be a multiple of this number (e.g., in units of 50). |
Stock Policies and Safety
| Field Name | Description |
|---|---|
| MaximumStockQty | The maximum stock limit for this product. |
| SafetyStockMethod | Fixed or daily-based safety stock method. |
| SafetyStockValue | Safety stock quantity. |
| SafetyTimeDays | Safety time: allows the product to be ordered earlier. |
| ScrapPercentage | Scrap rate (%) — for losses in production. |
Planning Behavior
| Field Name | Description |
|---|---|
| IsPhantom | Is it a phantom product? (Pseudo bill of materials; no production order is created). |
| PlanningTimeFenceGun | Time period closed to planning (e.g., MRP does not make changes within 7 days). |
| DemandTimeFenceGun | The maximum number of days for the validity of demands. |
| PlanlamaMetodu | Planning type on a product basis: MRP, ROP, Not Planned. |
| ReorderPointQty | Reorder point (valid for ROP). |
Links and Initial Data
| Field Name | Description |
|---|---|
| VarsayilanRotaID | The identity of the production route (workflow). |
| VarsayilanTedarikciID | The identity of the product's default supplier. |
| BaslangicStok | The current stock quantity in the system at the start of the MRP run. |
| GuvenlikStogu | Fixed safety stock value (can override SafetyStockValue). |
| LowLevelCode | The level code used in bills of materials (material resolution order). |
📌 Additional Information and Recommendations
- L4L (Lot for Lot): Orders exactly the amount required, without creating excess stock.
- FOQ (Fixed Order Quantity): A fixed quantity is always ordered (example: 1000 units).
- MAX: The lot is planned according to a certain upper limit.
- ROP (Reorder Point): A reorder point is set; it can operate independently of the MRP algorithm.
- Phantom Product: No production order is opened; sub-materials are planned directly (virtual product).
Defining these parameters correctly ensures that the MRP engine runs efficiently and accurately. Planning quality depends directly on the accuracy of these values.
The "Garbage In, Garbage Out" principle must not be forgotten: Planning done with incorrect data produces incorrect results.