MRP case studies
MRP · Put your knowledge to work in context.
MRP - Material Requirements Planning - is the discipline of turning demand for finished goods into a time-phased plan for components, materials, and capacity. The MRP certification exam tests whether a candidate can operate that logic rather than merely recite it: how a master production schedule feeds a bill of materials explosion, how netting and lot sizing convert gross requirements into planned orders, how lead times and item master data shape the result, and how capacity planning and exception messages close the loop. The MRP case studies are 5 cases and about 4,580 words.
1The 60-Unit Favor: ATP and the Frozen Zone at a Valve Assembly Line
A maker of hydraulic valve bodies runs one assembly line rated at 60 units per week and maintains an eight-week MPS for model BV-200 in weekly buckets. MPS receipts are currently W1 40, W2 40, W3 0, W4 60; on-hand is 30, safety stock 5, and the lot size is a fixed 40.
884 words, about 4 min2Why the Wheels Came Up 660 Short: Low-Level Codes, Scrap and Effectivity
A manufacturer builds the CT-500 utility cart: four wheels (WH-08), one handle assembly HA-12 (a phantom containing two grips GR-04 and one tube TB-02), plus an in-house paint step. The MRP run for a planned order of 500 carts due in W12 shows wheel gross requirement 2,000, on-hand 350, no scheduled receipts, and a planned order of 1,650.
950 words, about 5 min3Lot Size 5,000 vs EOQ at a Machined Bracket - With a Discount and an ECN Looming
A plant machines bracket BR-77 used in two product families. Annual demand is 12,000 units, average 231 per week, but it arrives lumpy: recent weeks ran 900, 100, 1,200, 0, 600, 350.
901 words, about 5 min4Rough-Cut Overload on the CNC Cell: Which Fix, and What the Coarse Model Missed
A machining cell with two CNC centres is the constraint for two MPS families, A and B. Each machine runs two 8-hour shifts, five days a week, giving 160 hours per week before a 10% planned maintenance allowance, so effective capacity is 144 hours per week.
930 words, about 5 min5Four Thousand Exception Messages a Week After Go-Live
Six weeks after an ERP go-live, a discrete manufacturer with 1,800 purchased part numbers is receiving about 4,200 MRP action messages per week: roughly 1,900 reschedule-in, 1,100 expedite, 700 cancel and 500 release. Planners have stopped working the list and instead react to the loudest buyer.
915 words, about 5 min