How do you handle MRP exceptions and changes in a timely and cost-effective manner?

As exce??es no MRP ocorrem quando os níveis reais de produ??o ou estoque diferem dos planejados, como escassez, excessos, atrasos ou cancelamentos. Identificar e priorizar essas exce??es rapidamente é crucial para garantir o atendimento aos pedidos dos clientes, otimizar os custos de estoque e usar a capacidade de forma eficiente. Concentrar-se nas exce??es mais críticas e urgentes, por meio de relatórios, alertas ou painéis do sistema MRP, é fundamental para minimizar o impacto no atendimento ao cliente, na lucratividade e na produtividade.

MRP exceptions are expected, and robust processes should be put in place to ignore the inevitable noise from these MRP outputs and focus on the meaningful ones, just like the summary states. An approach to prioritize exceptions should include closely monitoring single-source or long lead time items. Of course, transitioning as many items to kanban systems or a VMI approach eliminates this area of concern.

The biggest thing to effectively manage exceptions is to have: 1. Inventory accuracy. If you don't have control of your inventory then you'll only find out at the last minute there is a problem. 2. Check for possible substitutes. With our modular design sometimes it is quicker to rework something in stock than go outside to repurchase. 3. Have good relationships with your key suppliers. If you don't "cry wolf" then your good suppliers will be willing to help you in a pinch! 4. Focus on the "big picture". If an order has a shortage, then sometimes a short term solution is to reprioritize other orders that you can fulfill.

Automated Alerts: Set up real-time alerts within your MRP/ERP system to notify you of critical issues, such as stock shortages, late deliveries, or production delays. Exception-Based Reporting: Focus on exception reports that highlight deviations from the plan, like excess inventory or delayed orders, to prioritize urgent issues. Prioritize Based on Impact: Assess the impact of each exception (e.g., stockouts vs. delayed shipments) and focus on high-impact issues first to minimize costs and disruption.

As stated above, relying less on MRP for procurement via kanban systems or VMI has proven invaluable in my professional experience. Not all items can be moved to pull systems, but making a sincere effort to transition as many as possible, being open to the change, educating your suppliers, all lead to higher peace of mind and the ability to focus on those items difficult to move to kanban/VMI.

One critical area often overlooked is making the system be a requirement and not just the period at the end of the sentence. This leads to just checking a box saying the system is being used. It must be made a requirement for all actions/plans to be systematically driven so the problems/changes can be processed within MRP. Otherwise critical processes and decisions are not visible to all and the entire team ends up in firefighting mode every day.

Nice summary. It is important to understand the relationship between MRP challenges and how it will impact manufacturing planning. You will need to schedule firm you orders through your planning time fence. If component shortages are impacting manufacturing shortages, pull work forward to keep plant running until you can get required components.