MRP (Material Requirements Planning) Course

Lesson 1 • The Production Planning Hierarchy

Maps the planning levels from strategic to operational, showing where MRP fits. Clarifies how higher-level plans drive MRP inputs.

Lesson 2 • Manufacturing Environments and Strategies

Covers make-to-stock, make-to-order, and engineer-to-order environments. Connects production strategy to planning complexity and MRP applicability.

Lesson 3 • Demand Types and Inventory Concepts

Distinguishes independent from dependent demand and introduces core inventory terminology. Provides the conceptual basis for understanding MRP logic.

Lesson 1 • Bill of Materials Structure and Types

Explains single-level, multi-level, and modular BOMs and their impact on MRP explosion. Learners can construct and read a product structure tree.

Lesson 2 • Data Quality and Integrity Management

Addresses how data errors propagate through MRP outputs and how to prevent them. Learners apply audit techniques to validate MRP input data.

Lesson 3 • Master Production Schedule Fundamentals

Defines the MPS as the primary demand driver for MRP and explains its time-phased structure. Learners can read and interpret a basic MPS.

Lesson 1 • Developing the Master Production Schedule

Guides learners through building an MPS from a production plan and customer orders. Covers the mechanics of time-phased MPS record construction.

Lesson 2 • MPS Performance Metrics

Defines schedule attainment, customer service rate, and inventory turnover as MPS KPIs. Learners calculate and interpret these metrics to evaluate MPS quality.

Lesson 3 • Rough-Cut Capacity Check for MPS

Applies rough-cut capacity planning to validate the MPS before releasing it to MRP. Learners identify and resolve capacity conflicts at the MPS level.

Lesson 1 • Lead Time Offsetting and Time Phasing

Explains how planned order releases are offset by lead time to meet due dates. Learners calculate planned release dates across multi-level BOMs.

Lesson 2 • Gross-to-Net Requirements Calculation

Walks through netting on-hand inventory and scheduled receipts against gross requirements. This is the central arithmetic of every MRP calculation.

Lesson 3 • BOM Explosion and Multi-Level Planning

Demonstrates how parent planned orders generate child component requirements through BOM explosion. Learners trace requirements through three or more BOM levels.

Lesson 4 • Lot Sizing Techniques

Compares lot-for-lot, fixed order quantity, EOQ, and period order quantity methods. Learners select and apply the appropriate technique for a given scenario.

Lesson 1 • Load Profiles and Capacity Reports

Teaches construction and interpretation of load profiles and capacity requirement reports. Learners identify overloaded and underloaded periods visually and numerically.

Lesson 2 • Capacity Planning Levels Overview

Distinguishes rough-cut, resource requirements, and detailed CRP planning levels. Positions CRP as the validation step that follows MRP output.

Lesson 3 • Routing Data and Work Center Setup

Covers routing records, operation sequences, and work center capacity parameters. Accurate routing data is essential for valid CRP calculations.

Lesson 1 • Data Migration and Master Data Setup

Guides the process of loading BOMs, item masters, and routings into a new MRP system. Data completeness and accuracy at go-live determine early system success.

Lesson 2 • Testing and Parallel Running

Explains conference room pilots, simulation runs, and parallel operation before cutover. Learners design test scenarios that validate MRP logic and outputs.

Lesson 3 • User Training and Change Management

Addresses training planners, buyers, and production staff on MRP workflows. Effective change management drives adoption and sustains system benefits.

Lesson 1 • Converting Planned Orders to Firm Orders

Covers the decision rules and timing for firming planned purchase and production orders. Learners apply firm planned order logic to stabilize short-horizon schedules.

Lesson 2 • Shop Floor Execution and Feedback

Explains work order dispatch, priority sequencing, and production reporting back to MRP. Timely feedback keeps inventory records accurate and MRP valid.

Lesson 3 • Purchasing and Supplier Coordination

Connects MRP purchase order releases to supplier communication and delivery management. Learners use MRP data to negotiate lead times and manage supplier performance.

Lesson 1 • MRP Performance Measurement and Tuning

Defines KPIs for MRP effectiveness and guides systematic parameter tuning. Learners diagnose poor MRP performance and implement targeted improvements.

Lesson 2 • Distribution Requirements Planning

Extends MRP logic to multi-echelon distribution networks using DRP. Learners build DRP records and link distribution demand to manufacturing MRP.

Lesson 3 • Lean Manufacturing and MRP Coexistence

Resolves the apparent conflict between lean pull systems and MRP push logic. Learners design hybrid systems that use kanban for execution and MRP for planning.

Lesson 4 • MRP in an Integrated Business Environment

Examines MRP's interfaces with sales, finance, and quality management within ERP. Learners map cross-functional data flows and identify integration failure points.