MRP study plan

Map the full manufacturing planning hierarchy from strategic business plan through sales and operations planning, master production scheduling, material requirements planning, and production activity control, and state the time horizon and decision owner at each level

Distinguish independent demand from dependent demand and explain why MRP applies only to the dependent-demand portion of the product structure

Define the core MRP inputs and outputs and explain how gross requirements, scheduled receipts, projected on-hand, and net requirements flow through the planning engine

Work through five closed-book calculations converting a gross requirement into a net requirement using on-hand inventory and scheduled receipts

Write a one-paragraph explanation of MRP II versus ERP scope that a non-planner could follow

Construct a time-phased master production schedule for a make-to-stock item across a 12-period horizon, respecting the planning time fence and demand time fence

Classify products into make-to-stock, make-to-order, assemble-to-order, and engineer-to-order and explain how each changes MPS granularity and freezing rules

Aggregate and disaggregate demand between the S&OP family level and the end-item MPS level

Calculate available-to-promise for the first period and for a later period given a set of customer orders

Explain the consequences of nervous MPS behavior and describe two techniques that reduce schedule instability

Build a multi-level bill of materials for a product with at least three levels and assign correct level codes and low-level codes to every component

Explode a BOM to derive gross requirements at levels 0, 1, and 2 by hand and reconcile the totals against a parent-by-parent calculation

Differentiate single-level, indented, summarized, modular, and planning BOMs and identify which structure suits phantom assemblies and configurable products

Explain the role of phantom items, effectivity dates, and reference designators in BOM accuracy

Diagnose five common BOM errors such as wrong quantity per, missing scrap factor, and circular structure

Define every item master field that affects MRP: planning policy code, lot sizing rule, lead time, safety stock, scrap percentage, and ABC class

Calculate net requirements and planned order receipts and releases using lot-for-lot, fixed order quantity, and fixed period requirements on the same data set

Compare the inventory investment and order frequency produced by each lot sizing method and explain when each is appropriate

Distinguish manufacturing, cumulative, and purchased lead times and describe how queue and move time enter the offsetting calculation

Compute safety stock implications and explain the difference between safety stock and safety lead time

Run a full multi-period MRP record for at least three items and three periods, producing gross requirements, scheduled receipts, projected on-hand, net requirements, planned receipts, and planned releases

Interpret each standard action message type, including release, reschedule in, reschedule out, cancel, and expedite, and state the correct planner response

Explain exception messages and how pegging and where-used inquiries support root-cause analysis of a shortage

Design a weekly exception review routine that prioritizes messages by dollar impact and days of coverage

Identify when firm planned orders should be used instead of automatically generated planned orders

Distinguish rough-cut capacity planning from capacity requirements planning by inputs, time horizon, and level of detail

Calculate load, available capacity, and utilization for a work center across four periods and identify the overloaded period

Apply capacity smoothing options such as overtime, rerouting, splitting lots, and shifting the MPS, and state the trade-offs of each

Interpret a load profile and explain how a capacity bill and routing feed CRP

Explain the feedback loop from CRP back to the MPS and to the MRP plan

Identify the performance metrics that measure MRP health, including schedule adherence, planning bill accuracy, inventory record accuracy, fill rate, and MRP nervousness

Explain how inventory record accuracy above 95% is a precondition for trustworthy MRP output and describe one cycle counting method that achieves it

Describe how MRP data flows between modules in an ERP system, from order entry through purchasing, production, and costing

Outline the phases of an MRP or ERP implementation and the data migration and cutover risks specific to item master and BOM records

Diagnose why an MRP system produces bad recommendations even when the software is working correctly

Complete two full-length timed practice exams under exam conditions and score them by domain

Rework every missed question to the underlying concept and record the rule that was misapplied

Re-derive the ten most error-prone calculations from memory without notes, including ATP, netting, lot sizing, and load utilization

State the definition and one worked example for each of the 30 highest-frequency terms across all domains

Build a final one-page formula and definition sheet for last-day review