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What are the most effective ways to train employees on MRP usage?

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Material requirements planning (MRP) is a system that helps manufacturing operations plan and manage their inventory, production, and purchasing. MRP can improve efficiency, reduce waste, and optimize resources. However, MRP can also be complex and challenging to use, especially for employees who are not familiar with its features and functions. Therefore, training employees on MRP usage is essential for maximizing its benefits and avoiding errors and delays. In this article, we will discuss some of the most effective ways to train employees on MRP usage, based on best practices and common challenges.

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Amarpreet Singh

Founder @ Zenaca Consulting | Greenfield Manufacturing Operations | Plant Turnaround | SMT Expert | Electronics…
Natarajan Ramanathan

TPM & LEAN, WCM CLSSBB Consultant with handholding and implementation
Anita R.

1 Explain the benefits of MRP

Before you introduce employees to the technical aspects of MRP, you should explain the benefits of MRP for the organization and their roles. This can help employees understand the value and purpose of MRP, and motivate them to learn and apply it. You can use examples and scenarios to illustrate how MRP can help employees plan and execute their tasks, such as forecasting demand, scheduling production, ordering materials, tracking inventory, and managing quality. You can also highlight how MRP can reduce costs, improve customer satisfaction, and support strategic goals.

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S Vijay Venkatesh

Co-founder & MD @ Syscon Cronus - ERP | No-nonsense Mfg ERP | ERP Success & Turnaround specialist | Eat, Breath and Sleep ERP
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Manufacturing Industries with large number of multi Bom items and processes, Proper Production Plan followed by MRP is most crucial. This will optimise the Inventory and working capital. For proper MRP, live data of A. Made to order / made to stock with del schedules B. Order / stock allocation. C. Lead time for each Item 1. BOM based total required qty 2. Stocks at Stores/ WIP/ sub contact 3. Shipment/ bonding 4. Pending PO and Indents 5. Min stock The logic is 1 - (2+3+4) + 5 based on C for del date Auto purchase indent to be created. House keeping before MRP.. 1. Deleting all unwanted Purchase Indents, POs and SOs

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2 Choose the right training method

There are different methods of training employees on MRP usage, such as classroom sessions, online courses, webinars, videos, manuals, or simulations. You should choose the method that best suits your organization's needs, resources, and preferences. Some factors to consider are the number and location of employees, the complexity and frequency of MRP tasks, the availability and accessibility of trainers and materials, and the feedback and evaluation mechanisms. You can also combine different methods to create a blended learning approach that enhances retention and engagement.

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3 Customize the training content

MRP is a system that can be customized and configured to suit different manufacturing operations and processes. Therefore, you should customize the training content to match your organization's specific MRP settings, functions, and requirements. You can do this by using real data, examples, and scenarios from your organization, and focusing on the most relevant and frequently used MRP features and functions for each role and department. You can also use your organization's terminology, standards, and policies to make the training content more consistent and familiar.

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Eugene Siskoske, MBA

Purchasing Manager at H&H Swiss
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Creating MRP training that has been specifically tailored for the role of the end user has had the highest level of success in our company. The training must be highly relevant to the user and show them how to perform their job efficiently. This also requires that we use a sample of our organizations data in the training to quickly familiarize the end user with how the various functions of the system work together. I believe that both high-level and role-based training documentation should be created to provide end users with all the information they need to succeed.

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4 Provide hands-on practice

One of the most effective ways to train employees on MRP usage is to provide them with hands-on practice opportunities. This can help employees develop their skills and confidence in using MRP, and reinforce their learning outcomes. You can provide hands-on practice by using simulations, exercises, quizzes, or case studies that mimic real MRP tasks and situations. You can also use a sandbox or test environment that allows employees to explore and experiment with MRP without affecting the actual system or data.

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Anita R.
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One thing I’ve seen very helpful is to explain the key components to run MRP: accurate BOM (bills of materials): on hand inventory, lead times and demand (that could come from the master schedule or MPS). Calculate manually how to schedule production and deliveries for raw materials based on the key components mentioned above. For more information: please join ASCM Toronto or follow me on LinkedIn.

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5 Offer ongoing support

Training employees on MRP usage is not a one-time event, but a continuous process that requires ongoing support and guidance. You should offer ongoing support to employees by providing them with access to trainers, mentors, or experts who can answer their questions, troubleshoot their issues, or demonstrate best practices. You can also provide them with access to resources, such as manuals, videos, FAQs, or forums, that can help them refresh or update their knowledge and skills. You can also monitor and evaluate their performance and feedback, and adjust the training content and method accordingly.

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6 Encourage collaboration and communication

Another effective way to train employees on MRP usage is to encourage collaboration and communication among them. This can help employees learn from each other, share their experiences and insights, and solve problems together. You can encourage collaboration and communication by creating a learning community or network that connects employees who use MRP, and facilitating discussions, forums, or peer reviews. You can also promote a culture of learning and feedback that values and rewards employee contributions and improvements.

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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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Amarpreet Singh

Founder @ Zenaca Consulting | Greenfield Manufacturing Operations | Plant Turnaround | SMT Expert | Electronics Manufacturing Consultant | EMS Factory Setup |
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It is always top down. The top management needs to understand the ERP and talk the language which is used in ERP. The reports, methodology etc needs to be practiced first by the top management, only then the team below will start looking ERP as an enabler.

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Natarajan Ramanathan

TPM & LEAN, WCM CLSSBB Consultant with handholding and implementation
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ERP when properly used gives it's intended results. Management should have faith and respect for ERP. Then only they co-operate and collaborate with down the level team to use it properly. Each process of manufacturing should be parallely conducted in ERP with accuracy and speed

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Sriram K

DGM-Operations | Automotive | Lean specialist | TPM practitioner | Managerial excellence award winner
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On day-to -day review, the rejections, man-hour productivity, cycle time loss, equipment downtime, Power consumption etc must be derived in terms of value basis to realize our employees on resource usage.

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Kulvinder Singh Dhillon

Lead Manufacturing IT and Project Manager at Gates Corporation
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Need to explain the benefits in Biz Language and system processes like Forecast consumption, Demand consolidation, Safety stock planning, planning as per Lead Time etc. MRP data analysis for MIS reporting Top Management has to drive and ask for system generated approved planned orders.

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What are the most effective ways to train employees on MRP usage?

1

2

3

4

5

6

7

1 Explain the benefits of MRP

2 Choose the right training method

3 Customize the training content

4 Provide hands-on practice

5 Offer ongoing support

6 Encourage collaboration and communication

7 Here’s what else to consider

Manufacturing Operations

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What are the most effective ways to train employees on MRP usage?

1

2

3

4

5

6

7

1 Explain the benefits of MRP

2 Choose the right training method

3 Customize the training content

4 Provide hands-on practice

5 Offer ongoing support

6 Encourage collaboration and communication

7 Here’s what else to consider

Manufacturing Operations

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