{"id":12470,"date":"2025-10-14T21:07:38","date_gmt":"2025-10-14T19:07:38","guid":{"rendered":"https:\/\/sxe-consulting.com\/?page_id=12470"},"modified":"2025-10-14T21:07:38","modified_gmt":"2025-10-14T19:07:38","slug":"mrp-definition","status":"publish","type":"page","link":"https:\/\/sxe-consulting.com\/en\/glossaire-industriel\/mrp-definition\/","title":{"rendered":"What is MRP (Material Requirements Planning)?"},"content":{"rendered":"

Visit MRP (Material Requirements Planning)<\/strong>, or Component Requirements Planning<\/strong>, is an information and inventory management system designed to determine which raw materials and components<\/strong> are required, in what quantity<\/strong> and when<\/strong> to produce a finished product according to the established production plan.<\/p>\n

<\/p>\n

In-depth definition :<\/strong> MRP is the heart of planning in a production system. Flux Pouss\u00e9 (Push System)<\/strong>. It uses Bill of materials (BOM)<\/strong> of the product (list of components), the Master Production Plan (MPP)<\/strong> (what needs to be manufactured and when), and the state of stocks<\/strong> (which is already available) to generate purchase orders<\/strong> raw materials and production orders<\/strong> in-house. Its main role is to ensure that materials are available when needed for production, while minimizing inventory costs and stock-outs.<\/p>\n

The Three Fundamental Inputs of the MRP System<\/strong><\/h3>\n

To calculate production requirements, MRP relies on three sources of structured, integrated data, often managed via a system ERP (Enterprise Resource Planning)<\/strong> :<\/p>\n

A. Master Production Plan (MPP)<\/strong><\/h3>\n
    \n
  • Role :<\/strong> This is the highest level of planning. It indicates the demand for finished products over a given period (often 6 to 18 months). MPS is based on sales forecasts and firm orders.<\/li>\n<\/ul>\n

    B. Bill of Materials (BOM)<\/strong><\/h3>\n
      \n
    • Role :<\/strong> MRP needs to know the tree structure and the exact quantity of each component and sub-assembly required to assemble a unit of finished product. An accurate BOM, often derived from the\u2019Industrialisation<\/strong> and formalized in the Manufacturing file<\/strong>, is essential for accurate calculations.<\/li>\n<\/ul>\n

      C. Inventory Status File<\/strong><\/h3>\n
        \n
      • Role :<\/strong> It records current stock levels for each item, including physical stocks, quantities on order, and quantities already allocated to other production orders.<\/li>\n<\/ul>\n

        MRP calculation and execution<\/strong><\/h3>\n

        The MRP system performs a calculation by fragmented needs<\/strong> (called Nettage<\/em>). It starts with the gross requirements for finished products (from the PDP), deducts what is already in stock (B), and uses the BOM to calculate the dependent requirements for sub-assemblies and raw materials. The final result is a set of recommendations:<\/p>\n

          \n
        1. Planned Production Orders :<\/strong> For components manufactured in-house (with the necessary launch and delivery dates).<\/li>\n
        2. Planned Purchase Orders :<\/strong> For raw materials and parts purchased from suppliers (with necessary order and receipt dates).<\/li>\n<\/ol>\n

          MRP, Digitization and Performance Improvement<\/strong><\/h3>\n

          Although MRP is intrinsically linked to the Flux Pouss\u00e9<\/strong>, optimization is essential for any manufacturing company:<\/p>\n

            \n
          • Rupture Reduction :<\/strong> The main objective of MRP is to ensure the availability of parts at the time of production, eliminating wastage (Muda<\/em>) criticism: waiting due to lack of material.<\/li>\n
          • Planning optimization :<\/strong> The engineers at Industrial Engineering<\/strong> can use MRP to simulate the impact of changes in demand or supply on the Manufacturing range<\/strong>, helping to identify potential overload periods and Choke bolts<\/strong> in the value chain.<\/li>\n<\/ul>\n

            Evolution to MRP II (Manufacturing Resource Planning)<\/strong><\/h3>\n

            MRP has evolved into MRP II, which is a much more comprehensive system, integrating not only materials, but also production capabilities<\/strong> (Capacity Requirements Planning - CRP). MRP II seeks to validate whether the company has not only the parts, but also the machine time and human resources needed to execute the plan, thus providing a more global view of the company's business.\u2019Operational Excellence<\/strong>.<\/p>\n

            Link with Manufacturing Execution Systems (MES)<\/strong><\/h3>\n

            MRP generates production orders for finished products. These orders are then transmitted to the MES (Manufacturing Execution System)<\/strong>, who is responsible for detailed execution on the shop floor, data collection via the\u2019IoT<\/strong>, and real-time monitoring. MRP and MES form the planning and execution loop in the digital architecture.<\/p>\n

            The role of the digital transformation consultant<\/strong><\/h3>\n

            Incorrect MRP implementation or configuration leads to poor inventory sizing (too much unnecessary stock or shortages). The digital transformation consultant also intervenes to :<\/p>\n

              \n
            • Making the BOM more reliable:<\/strong> Ensuring the accuracy of Parts list<\/strong> and Manufacturing file<\/strong>.<\/li>\n
            • Optimize Settings :<\/strong> Define the right lead times and batch sizes (often smaller, to achieve the best possible results). Pulled Flow<\/strong> when possible) and safety stock policies.<\/li>\n
            • Align planning and execution :<\/strong> Ensure that MRP and MES communicate correctly for decision-making based on reliable data.<\/li>\n<\/ul>\n

              In conclusion, the MRP<\/strong> is the mathematical tool that manages the \u201cwhen\u201d and \u201cwhat\u201d of procurement. Mastering it is essential to transform planning into smooth, profitable execution.<\/p>\n

              <\/p>","protected":false},"excerpt":{"rendered":"

              Le MRP (Material Requirements Planning), ou Planification des Besoins en Composants, est un syst\u00e8me de gestion de l’information et des stocks qui a pour objectif de d\u00e9terminer quelles mati\u00e8res premi\u00e8res et composants sont n\u00e9cessaires, en quelle quantit\u00e9 et \u00e0 quel moment pr\u00e9cis pour fabriquer un produit fini selon le plan de production \u00e9tabli.<\/p>","protected":false},"author":1,"featured_media":0,"parent":12324,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_sitemap_exclude":false,"_sitemap_priority":"","_sitemap_frequency":"","footnotes":""},"definition":[99],"class_list":["post-12470","page","type-page","status-publish","hentry","definition-definition"],"jetpack_sharing_enabled":true,"_links":{"self":[{"href":"https:\/\/sxe-consulting.com\/en\/wp-json\/wp\/v2\/pages\/12470","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/sxe-consulting.com\/en\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/sxe-consulting.com\/en\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/sxe-consulting.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/sxe-consulting.com\/en\/wp-json\/wp\/v2\/comments?post=12470"}],"version-history":[{"count":0,"href":"https:\/\/sxe-consulting.com\/en\/wp-json\/wp\/v2\/pages\/12470\/revisions"}],"up":[{"embeddable":true,"href":"https:\/\/sxe-consulting.com\/en\/wp-json\/wp\/v2\/pages\/12324"}],"wp:attachment":[{"href":"https:\/\/sxe-consulting.com\/en\/wp-json\/wp\/v2\/media?parent=12470"}],"wp:term":[{"taxonomy":"definition","embeddable":true,"href":"https:\/\/sxe-consulting.com\/en\/wp-json\/wp\/v2\/definition?post=12470"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}