| Item Code | Material | Project MPS (MTO) |
Forecast MPS (MTS) |
BOM Req | Stock On Hand | SCH PO | Open WO | Total Available | Net Requirement | Lead Time (Days) |
Required Date | PO Release Date | MRP Action | Status | Formula Logic |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| RM-001 | MS PLATE 12MM | 500 | 200 | 700 | 150 | 100 | 50 | 300 | 400 | 12 | 15-May-2026 | 03-May-2026 | Release New PO | SHORTAGE | (BOM Req) - (SOH + SCH PO + WO) |
| RM-002 | PIPE 4 INCH | 300 | 100 | 400 | 600 | 0 | 0 | 600 | -200 | 8 | 18-May-2026 | - | No Action | SUFFICIENT | 400 - 600 |
| RM-003 | ELBOW 90 DEG | 1200 | 500 | 1700 | 300 | 400 | 200 | 900 | 800 | 20 | 20-May-2026 | 30-Apr-2026 | Urgent PO + Expedite | CRITICAL | 1700 - (300+400+200) |
| RM-004 | WELDING ROD | 100 | 300 | 400 | 200 | 250 | 0 | 450 | -50 | 5 | 25-May-2026 | - | Maintain Stock | SAFE | 400 - 450 |
| RM-005 | FLANGE 6 INCH | 600 | 300 | 900 | 250 | 100 | 100 | 450 | 450 | 15 | 17-May-2026 | 02-May-2026 | Raise RFQ | PLAN PROCUREMENT | 900 - 450 |
| RM-006 | PAINT RED OXIDE | 150 | 50 | 200 | 25 | 0 | 0 | 25 | 175 | 10 | 12-May-2026 | 02-May-2026 | Immediate Procurement | CRITICAL | 200 - 25 |
| MRP Logic | Formula | Purpose |
|---|---|---|
| Gross Requirement | Project MPS + Forecast MPS | Total demand generation |
| BOM Explosion | FG Qty × BOM Qty | Raw material calculation |
| Total Available | Stock + SCH PO + Open WO | Available inventory |
| Net Requirement | BOM Requirement - Total Available | Actual shortage |
| PO Release Date | Required Date - Lead Time | Backward scheduling |
| Safety Stock Check | IF(Stock < ROP) | Reorder planning |
| Procurement Priority | Criticality + Delay Risk + Vendor LT | AI purchase prioritization |
| Condition | ERP Auto Action | Department |
|---|---|---|
| Net Requirement > 0 | Create Purchase Requisition | SCM |
| Lead Time Exceeded | Generate Expedite Ticket | Procurement |
| Critical Production Item Shortage | Escalation to Project Head | PMS |
| Vendor Delay Risk | Vendor Follow-Up Reminder | Purchase |
| Material Available in Another Plant | Generate STO Request | Stores |
| Engineering BOM Change | BOM Revision Ticket | Engineering |
| Forecast Spike | Advance Procurement Suggestion | Planning |
| Stock Below ROP | Auto Reorder Trigger | MRP Scheduler |
| Step | ERP Process |
|---|---|
| 1 | Read Project MPS + Forecast MPS |
| 2 | Explode BOM Requirements |
| 3 | Check Current Inventory |
| 4 | Check Scheduled Purchase Orders |
| 5 | Calculate Net Requirement |
| 6 | Apply Lead Time Scheduling |
| 7 | Create PR / RFQ / PO Recommendations |
| 8 | Generate AI Tickets & Escalations |
| 9 | Monitor Supplier Deliveries |
| 10 | Continuously Recalculate MRP |