Last updated on 2024年9月27日

How do you validate the accuracy of your MRP data?

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Material requirements planning (MRP) is a system that helps you plan and manage your inventory, production, and purchasing activities. It uses data from your bill of materials (BOM), master production schedule (MPS), and inventory records to calculate the quantities and timings of materials, components, and finished goods you need. However, if your MRP data is inaccurate, outdated, or inconsistent, you may face problems such as stockouts, excess inventory, delays, or quality issues. That's why it's important to validate the accuracy of your MRP data regularly and fix any errors or gaps. Here are some steps you can follow to audit your MRP system and improve its performance.

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Gricel Martínez

Planning Manager |Gerente de Planeación de materiales |Planeación del Suministro |Planeación de la producción |Cadena…
Gabriel José de Souza

Compras | Strategic Sourcing | Supply Chain | Inteligência de Suprimentos | Gest?o de Estoques
José Octavio Balleza Gómez

Supply Chain Director | Transportation Distribution Logistics, Procurement | Operations | Regional SC Latam Americas |…

1 Review your BOM

Your BOM is the backbone of your MRP system, as it defines the materials and components that go into each product and their relationships. A faulty BOM can lead to inaccurate demand forecasts, wrong order quantities, or wasted resources. To validate your BOM, you should check for errors such as missing items, incorrect quantities, duplicate entries, obsolete parts, or wrong units of measure. You should also verify that your BOM reflects the current design and engineering specifications of your products and that it is aligned with your MPS and inventory records.

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Gabriel José de Souza

Compras | Strategic Sourcing | Supply Chain | Inteligência de Suprimentos | Gest?o de Estoques
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Sim, a lista técnica desempenha um papel fundamental no MRP, pois define os materiais e componentes necessários para fabricar cada produto. Uma lista técnica imprecisa pode resultar em previs?es de demanda erradas, quantidades de pedidos incorretas ou desperdício de recursos. Para validar a lista técnica, é essencial verificar a presen?a de erros, como itens ausentes, quantidades incorretas, duplicatas, pe?as obsoletas ou unidades de medida incorretas. Além disso, é importante garantir que a lista técnica esteja alinhada com as especifica??es atuais de projeto e engenharia dos produtos, bem como com os registros de MPS (Plano Mestre de Produ??o) e inventário, para garantir uma opera??o eficiente e precisa do MRP.

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Gricel Martínez

Planning Manager |Gerente de Planeación de materiales |Planeación del Suministro |Planeación de la producción |Cadena de Suministro | Supply Chain | Planeación estratégica |Optimización de inventarios y procesos
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La revisión continua de la integridad de la BOM, coherencia con los procesos de ingeniería y sincronización con las políticas de inventario son fundamentales para optimizar los resultados. una práctica clave es llevar a cabo auditorías regulares de la BOM para identificar discrepancias entre la lista teórica y lo que realmente sucede en el piso de producción.

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2 Update your MPS

Your MPS is the plan that specifies the quantity and timing of each product you want to produce and deliver to your customers. It drives your MRP calculations and determines your material requirements and order releases. To validate your MPS, you should ensure that it is based on reliable demand forecasts, customer orders, and market conditions. You should also update your MPS frequently to account for any changes in demand, capacity, or availability. You should also compare your MPS with your actual production output and delivery performance and identify any deviations or bottlenecks.

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Gricel Martínez

Planning Manager |Gerente de Planeación de materiales |Planeación del Suministro |Planeación de la producción |Cadena de Suministro | Supply Chain | Planeación estratégica |Optimización de inventarios y procesos
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La BOM debe estar directamente alineada con el Plan Maestro de Producción. El MPS es la base sobre la cual se generan las órdenes de producción y cualquier desalineación entre el MPS y la BOM puede provocar un desbalance en los requerimientos de materiales, lo que se traduce en inventarios inadecuados, sobreproducción o falta de materiales críticos en momentos clave. Es crucial que la lista de materiales sea coherente con las expectativas de demanda, tiempos de ciclo y capacidades de producción.

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3 Monitor your inventory

Your inventory records are the source of information about the current status and location of your materials, components, and finished goods. They affect your MRP calculations and influence your replenishment decisions and inventory levels. To validate your inventory records, you should conduct regular physical counts and reconciliations with your MRP system and correct any discrepancies or inaccuracies. You should also track your inventory turnover, aging, and obsolescence and adjust your inventory policies and parameters accordingly.

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Gricel Martínez

Planning Manager |Gerente de Planeación de materiales |Planeación del Suministro |Planeación de la producción |Cadena de Suministro | Supply Chain | Planeación estratégica |Optimización de inventarios y procesos
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El monitoreo constante del inventario es un pilar fundamental para garantizar la precisión del sistema MRP y la eficiencia en la planificación de materiales. Los registros de inventario no solo proporcionan información clave sobre la disponibilidad de los materiales y productos, sino que también influyen directamente en las decisiones de reabastecimiento, optimización del capital de trabajo y cumplimiento de los plazos de producción. Para tener un monitoreo eficaz implementar recuentos físicos regulares, controlar la rotación de inventario y ajustar las políticas de inventario permite reducir costos asociados a exceso o falta de stock.

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4 Evaluate your suppliers

Your suppliers are the partners that provide you with the materials and components you need for your production. They impact your MRP calculations and affect your lead times, quality, and costs. To validate your supplier data, you should assess their performance and reliability based on criteria such as delivery time, quality, price, responsiveness, and flexibility. You should also communicate with your suppliers regularly and share your MRP data and forecasts with them to ensure alignment and collaboration.

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José Octavio Balleza Gómez

Supply Chain Director | Transportation Distribution Logistics, Procurement | Operations | Regional SC Latam Americas | GBS SSO GCC ? Pharma | Med Devices | Chemical | Cosmetic | Healthcare | Food & Beverage
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Suppliers evaluation in several aspects beyond lead time is key to the accuracy of the MRP. In all industries it is critical therefore, it is imperative to ensure a periodic review of all the parameters gotten from Suppliers Evaluation and its relationship with MRP. Failure to comply with suppliers evaluation take supply chains to ineffective management and MRP miscalculations.

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5 Analyze your reports

Your reports are the outputs of your MRP system that help you monitor and control your inventory, production, and purchasing activities. They include reports such as planned orders, order releases, action messages, exception messages, and performance indicators. To validate your reports, you should review them periodically and verify that they are accurate, complete, and relevant. You should also use your reports to identify and resolve any issues or opportunities for improvement in your MRP system and processes.

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Ahmed Elsayed

Experienced nearly 11 yrs in Supply Chain Management Planning & Procurement Senior Supply Chain Specialist | Senior Buyer& Procurement |Supply Chain team leader, Inventory Managment |SAP MM, SAP Purchasing, SAP S/4HANA
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Run MRP Exception Reports Exception reports flag potential issues in the planning process: Stockouts or Shortages: Identify products that frequently face shortages or stockouts, indicating issues with either forecasting or order recommendations. Excess Inventory: Highlight items where the system consistently suggests overstocking, leading to excess inventory costs. Late Orders: Analyze reports for orders that are consistently running late. This can indicate issues with lead time data or vendor performance. -Validate Historical Data Against MRP Outputs Compare Planned vs. Actual Orders: Compare the orders suggested by MRP with actual purchase orders and production requirements. Any large deviations should prompt investigation.

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6 Implement your improvements

Validating your MRP data is not a one-time event, but a continuous process that requires regular feedback and action. To ensure that your MRP system remains accurate and effective, you should implement the improvements that you identify from your validation steps and measure their impact on your inventory, production, and purchasing performance. You should also document and communicate your improvements and best practices to your stakeholders and users and train them on how to use your MRP system properly and efficiently.

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Wesley Barros

Analista de PCP Pleno na PKG Brasil | Planejamento e Controle da Produ??o | Inventário | Lean Six Sigma
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Para validar a precis?o dos dados MRP, é essencial revisar regularmente as previs?es de demanda, atualizar os níveis de estoque e verificar os lead times com fornecedores. Implementar melhorias como a integra??o de sistemas ERP, uso de ferramentas de Business Intelligence para análise de dados, e treinamento contínuo da equipe pode aumentar a precis?o. Além disso, realizar auditorias periódicas e usar técnicas de controle estatístico ajudam a identificar e corrigir desvios rapidamente.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Ali Raza, MBA, PMP?

Supply Chain Leader @ Obeikan Investment Group xP&G | Supply Chain Management, Operation Manufacturing Excellence
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To validate the accuracy of your MRP data, conduct regular physical counts and reconcile them with your inventory records. Monitor key metrics such as inventory turnover, aging, and obsolescence. Address any discrepancies promptly and adjust your inventory policies as needed to ensure accuracy and efficiency.

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How do you validate the accuracy of your MRP data?

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1 Review your BOM

2 Update your MPS

3 Monitor your inventory

4 Evaluate your suppliers

5 Analyze your reports

6 Implement your improvements

7 Here’s what else to consider

Material Requirements Planning (MRP)

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