Mastering Material Requirements Planning for Modern Manufacturing Success
You’re under pressure. Inventory is piling up or running short. Production schedules are reactive, not strategic. Customer deliveries are slipping. You're not alone – most manufacturing leaders face this silent crisis, where outdated planning methods erode margins and damage reputations. Every day without a precise, modern MRP system means more wasted capital, more missed opportunities, and more risk of obsolescence in an era where agility equals survival. You don't need generic theory. You need a step-by-step blueprint to build, deploy, and master a world-class Material Requirements Planning system that aligns inventory, capacity, and demand. That’s exactly what this course delivers. Mastering Material Requirements Planning for Modern Manufacturing Success is your structured path from firefighting to future-proofing – turning chaotic planning into a strategic asset that drives efficiency, reduces cost, and earns board-level recognition. Samira Chen, Senior Operations Manager at a mid-tier automotive parts manufacturer, used the methods in this course to reduce inventory holding costs by 32% within four months while improving on-time delivery from 76% to 98%. No new software. No massive IT overhaul. Just disciplined MRP mastery. This isn’t about legacy MRP. It’s about mastering dynamic, responsive planning that fits today’s volatile supply chains, lean principles, and digital manufacturing environments. You’ll gain clarity, control, and the confidence to lead with precision. The result? You go from overwhelmed and reactive to empowered and proactive – delivering a board-ready MRP implementation roadmap in as little as 30 days, backed by a globally recognised Certificate of Completion. Here’s how this course is structured to help you get there.Course Format & Delivery Details Learn On Your Terms – No Deadlines, No Pressure
This course is self-paced, with secure on-demand access that begins immediately after enrollment. There are no fixed schedules, mandatory attendance, or time zone restrictions. Learn at your own speed, on your own timeline, whether you’re in Singapore, Stuttgart, or São Paulo. Most learners complete the core curriculum in 20 to 25 hours, with immediate implementation of high-impact tools starting within the first 2 hours. Real results – such as accurate demand forecasting, reduced stockouts, and optimised lead-time planning – are consistently reported within 30 days of starting. Lifetime Access – Including All Future Updates
Enrol once, and you retain lifetime access to the entire course. That includes all future content updates, methodology refinements, and expanded case studies – delivered at no additional cost. As manufacturing planning evolves, so does your mastery. Access is fully mobile-friendly, with responsive design so you can study from your tablet on the shop floor or review checklists from your phone during downtime. No downloads. No installations. Just proven strategies, available anytime, anywhere. Robust Support & Expert Guidance
Every learner receives direct, instructor-led support throughout the course. You’re not navigating this alone. Submit questions, request clarification on complex topics like multi-level BOM explosion or safety stock modelling, and receive detailed, personalised guidance within 24 business hours. Our expert facilitators are seasoned manufacturing operations specialists with 15+ years of hands-on MRP deployment across discrete and process manufacturing sectors. They don’t teach theory – they teach what works in the real world. Certificate of Completion – Issued by The Art of Service
Upon finishing the course, you will earn a Certificate of Completion issued by The Art of Service – a globally recognised credential respected by employers, auditors, and industry partners. This certification validates your mastery of modern MRP principles and signals operational excellence to leadership and peers. The certificate includes a unique verification ID and is formatted for LinkedIn and professional portfolios, enhancing visibility and career opportunity. Transparent Pricing – No Hidden Fees
Pricing is straightforward and all-inclusive. There are no recurring charges, no subscription fees, and no surprise costs. The price you see is the price you pay, with no upsells or hidden add-ons. We accept all major payment methods, including Visa, Mastercard, and PayPal, with encrypted, PCI-compliant transactions to ensure your data is protected. 100% Satisfied or Refunded – Zero Risk enrollment
You’re fully protected by our no-questions-asked, 30-day money-back guarantee. If you complete the first three modules and feel the course doesn’t deliver exceptional value, contact us for a full refund. No hassle, no risk. Your success is our priority – and we stand behind every lesson with absolute confidence. Seamless Enrollment & Access
After enrolling, you’ll receive a confirmation email. Your access details will be sent separately once the course materials are fully prepared for your optimal learning experience. There’s no wait for content delivery – your journey begins the moment your access is activated. Will This Work for Me?
Yes – even if you’re not an MRP expert, even if previous attempts at planning improvement failed, even if your ERP system is outdated or inconsistent. This course works even if you manage a small workshop with limited digital tools, because it focuses on core principles, manual validation techniques, and phased digital integration. Operations supervisors, plant managers, supply chain analysts, and procurement leads have all achieved breakthrough results. With 4,800+ manufacturing professionals trained globally, our learners report higher job satisfaction, faster decision-making, and improved cross-functional alignment. This is not theory – it’s a proven system that scales from SMEs to enterprise-level production.
Module 1: Foundations of Modern Material Requirements Planning - Understanding the core purpose of MRP in today’s manufacturing landscape
- Evolution from MRP I to MRP II and beyond: What's changed and why it matters
- Key differences between traditional and modern MRP approaches
- Aligning MRP with Lean, Six Sigma, and Industry 4.0 principles
- The role of MRP in preventing overproduction and understocking
- Common myths and misconceptions about Material Requirements Planning
- Defining planning horizons, time fences, and planning cycles
- Understanding the difference between independent and dependent demand
- How MRP fits within ERP, MES, and supply chain ecosystems
- Identifying organisational pain points that MRP can solve
- Recognising early warning signs of an ineffective MRP system
- Overview of the MRP decision-making hierarchy: strategic, tactical, operational
- Introducing the MRP success framework used by leading manufacturers
- Setting realistic, measurable goals for MRP implementation
- Creating stakeholder buy-in and cross-functional alignment
Module 2: Master Data Management for Accurate MRP - The critical role of master data accuracy in MRP reliability
- Ensuring Bill of Materials (BOM) completeness and structure integrity
- Single-level vs. multi-level BOMs: when to use each
- Validating routing data: operation sequences, work centres, and lead times
- Setting and auditing inventory records: on-hand, committed, in-transit
- Managing item master data: part numbers, descriptions, and classifications
- Establishing data governance policies for master file ownership
- Using checklists for regular data health assessments
- Calculating data accuracy KPIs and setting targets
- Correcting common data errors that derail MRP outputs
- Process for regular BOM audits and engineering change order integration
- Handling alternate routings and substitute materials
- Managing phantom assemblies and planning items
- Linking product lifecycle stages to MRP parameters
- Documenting and standardising master data procedures
Module 3: Demand Management & Forecasting for MRP - Integrating sales forecasts into the MRP process
- Distinguishing between forecast-driven and order-driven production
- Choosing the right forecasting method: moving average, exponential smoothing, trend projection
- Qualitative inputs for demand planning: sales team input, market trends
- Using historical data to refine forecast accuracy
- Calculating forecast error metrics: MAPE, MAD, MSE
- Setting safety factors based on forecast volatility
- Incorporating customer-specific contracts and blanket orders
- Managing promotions, campaigns, and seasonal spikes
- Consensus forecasting techniques across sales, marketing, and operations
- Introduction to Sales & Operations Planning (S&OP) alignment
- Setting time-phased demand profiles in the master schedule
- Managing forecast consumption rules
- Updating forecasts dynamically without destabilising MRP
- Best practices for forecast review and adjustment cycles
Module 4: Master Production Scheduling (MPS) Deep Dive - The role of the MPS as the driver of MRP
- Developing a realistic, achievable master production schedule
- Time fencing: demand, planning, and freeze zones
- Setting and communicating the final assembly schedule
- Resolving conflicting priorities between sales and production
- Capacity-checking the MPS using rough-cut capacity planning (RCCP)
- Adjusting the MPS based on resource availability and backlog
- Managing engineering changes mid-schedule
- Handling rush orders and expedited requests
- Prioritisation techniques for order sequencing
- Integrating customer lead time commitments into the MPS
- How the MPS supports order promising and ATP logic
- Running what-if scenarios for schedule adjustments
- Documenting MPS revisions and approvals
- Linking MPS updates to procurement and capacity planning
Module 5: The MRP Engine – Logic, Inputs, and Outputs - Step-by-step walkthrough of MRP calculation logic
- Understanding gross requirements and scheduled receipts
- Calculating projected on-hand inventory over time
- Determining net requirements for each period
- Applying lead time offsetting to generate planned order releases
- Lot sizing techniques: Lot-for-Lot, EOQ, Fixed Order Quantity, Period Order Quantity
- Handling minimum order quantities and supplier constraints
- Understanding time-phased planning and bucketing periods
- Interpreting MRP planned orders, rescheduling notices, and cancellations
- Managing exceptions and alerts in MRP outputs
- Setting action messages and due-date warnings
- Resolving rescheduling suggestions: expedite, delay, cancel
- How MRP interacts with capacity planning systems
- Ensuring MRP runs are properly sequenced and timed
- Validating MRP output against shop floor realities
Module 6: Inventory Management & Optimisation - Principles of inventory types: raw, WIP, finished goods, MRO
- Setting appropriate inventory targets based on demand variability
- Calculating safety stock using statistical methods
- Setting reorder points and order-up-to levels
- Managing cycle counting programs to ensure accuracy
- Reducing obsolete and excess inventory through MRP discipline
- Differentiating between cycle stock, safety stock, and pipeline stock
- Using ABC analysis to prioritise inventory control efforts
- Inventory turnover benchmarks and improvement targets
- Carrying cost calculation and financial impact of inventory decisions
- Linking inventory policy to supplier performance and lead time
- Integrating vendor-managed inventory (VMI) with internal MRP
- Using min/max systems in conjunction with MRP
- Best practices for consignment inventory tracking
- Strategies for reducing inventory without risking service levels
Module 7: Capacity Planning & Load Management - Distinguishing between capacity planning levels: resource planning, RCCP, CRP
- Defining key capacity units: machine hours, labour hours, shifts
- Mapping routings to work centres and capacity models
- Calculating rated capacity vs. demonstrated capacity
- Identifying critical work centres and bottleneck management
- Using finite vs. infinite loading in capacity analysis
- Developing time-phased capacity load reports
- Visualising capacity vs. load using histograms and dashboards
- Resolving capacity constraints: overtime, subcontracting, rescheduling
- Linking CRP outputs to detailed shop floor schedules
- Managing shared resources across multiple product lines
- Planning for maintenance and downtime in capacity models
- Adjusting capacity plans based on MRP-driven requirements
- Using buffer management to absorb variability
- Performance monitoring: utilisation, efficiency, and throughput
Module 8: Procurement & Supplier Integration - Translating MRP outputs into actionable purchase requirements
- Critical path analysis for long-lead items
- Managing supplier lead times and variability
- Creating reliable purchase schedules from planned orders
- Handling make-vs-buy decisions using MRP data
- Integrating blanket orders and contract pricing with MRP
- Synchronising supplier deliveries with production needs
- Managing quality holds and receiving delays in the MRP cycle
- Tracking supplier performance: on-time delivery, quality yield
- Using MRP to support strategic sourcing initiatives
- Preparing for supplier disruptions using safety time buffers
- Managing dual sourcing and alternate vendors in the system
- Aligning procurement cycles with MRP planning buckets
- Handling international logistics and customs delays
- Best practices for purchase order release and follow-up
Module 9: Shop Floor Control & Production Execution - Closing the loop between MRP and actual shop floor activity
- Shop order generation from planned production releases
- Work order documentation and release procedures
- Tracking order progress: started, in process, completed
- Reporting actual material consumption vs. standard BOMs
- Recording actual labour and machine time used
- Managing scrap, rework, and yield variances
- Updating WIP balances and adjusting future MRP runs
- Integrating kitting and material staging with MRP
- Using visual management tools to support MRP execution
- Managing make-to-order, make-to-stock, and engineer-to-order models
- Coordinating with maintenance scheduling for tooling and dies
- Handling rework orders and non-conformance reports
- Updating MRP with actual completion dates
- Using shop floor feedback to refine BOMs and routings
Module 10: Performance Measurement & KPIs - Defining KPIs that reflect MRP system health
- On-time delivery to customer: definition, calculation, tracking
- Inventory accuracy: cycle count adherence and variance rates
- Planned order execution rate and schedule adherence
- MRP system nervousness: causes and reduction strategies
- Forecast accuracy and its impact on MRP stability
- Supplier on-time delivery performance
- Production schedule attainment and bottleneck utilisation
- Scrap and rework rates relative to MRP plans
- Order cycle time from release to completion
- Backlog management and visibility
- Reporting dashboards and executive summary metrics
- Setting baseline, target, and stretch goals for each KPI
- Benchmarking against industry standards
- Using KPIs to drive continuous improvement cycles
Module 11: Advanced MRP Techniques & Edge Cases - Managing remanufacturing and reverse logistics in MRP
- Planning for kits, sets, and configurable products
- Multi-plant MRP: consolidating requirements across locations
- Intercompany transfer planning and material flows
- Co-product and by-product planning
- Handling lot traceability and serialised components
- Regulated environments: MRP for FDA, ISO, or AS9100 compliance
- Planning for product recalls and containment actions
- Managing phased product introductions and end-of-life transitions
- Using MRP for project-based manufacturing
- Planning for service parts and aftermarket demand
- Integrating MRP with drop shipping and 3PL networks
- Managing consignment inventory in the planning system
- Remote work centre scheduling and subcontractor management
- Scenario planning for mergers, plant closures, or relocations
Module 12: MRP & Digital Transformation - How MRP integrates with modern ERP systems like SAP, Oracle, NetSuite
- Leveraging cloud-based MRP platforms for real-time updates
- Using APIs to connect MRP with CRM and supply chain tools
- Automating MRP runs and exception reporting
- Introducing predictive analytics to enhance forecasting
- Using machine learning to identify demand anomalies
- IoT sensors and real-time machine data in capacity planning
- Digital twin applications for MRP simulation and testing
- Barcode and RFID integration for inventory accuracy
- Mobile applications for shop floor data entry and MRP updates
- Integrating MRP with business intelligence and Power BI
- Building custom alerts and dashboards for MRP performance
- Ensuring data security and user access controls
- Change management strategies for digital MRP adoption
- Future trends: AI-driven replenishment and autonomous planning
Module 13: Implementation Roadmap & Change Management - Phased rollout strategy: pilot, transition, full deployment
- Creating a project charter for MRP implementation
- Building a cross-functional implementation team
- Defining roles and responsibilities for MRP ownership
- Conducting readiness assessments and gap analysis
- Developing training programs for planners, buyers, and supervisors
- Running parallel systems during transition period
- Managing resistance to new processes and tools
- Communicating benefits and progress to stakeholders
- Setting up a continuous improvement feedback loop
- Using Kaizen events to refine MRP processes
- Creating standard operating procedures for ongoing management
- Establishing governance and MRP audit processes
- Monitoring adoption rates and user engagement
- Scaling MRP across multiple product lines or divisions
Module 14: Troubleshooting & Sustaining MRP Success - Diagnosing common MRP failures and their root causes
- Fixing “nervous” MRP systems with improper lot sizing
- Resolving data accuracy issues causing planning errors
- Addressing user non-compliance and bypassing of processes
- Reducing excessive rescheduling and system instability
- Managing master data corruption and uncontrolled changes
- Correcting BOM and routing errors in active systems
- Dealing with legacy system limitations and workarounds
- Recovering from inventory count discrepancies
- Handling sudden demand surges or supply disruptions
- Restoring trust in MRP after past failures
- Conducting root cause analysis using 5 Whys and fishbone diagrams
- Using Pareto analysis to prioritise system fixes
- Establishing a monthly MRP health review process
- Building a culture of data integrity and continuous improvement
Module 15: Certification, Next Steps & Career Advancement - Final assessment: evaluating your MRP system design and logic
- Submitting a comprehensive MRP implementation proposal
- Receiving feedback from instructor on your project
- Skills validation and mastery confirmation
- Earning your Certificate of Completion issued by The Art of Service
- Sharing your certification on LinkedIn and job platforms
- Using your MRP expertise in performance reviews and promotions
- Positioning yourself for roles in supply chain leadership
- Networking with other certified manufacturing professionals
- Accessing alumni resources and industry updates
- Continued learning pathways: APICS, CSCP, Lean Master
- Integrating MRP mastery into operational excellence programs
- Using your credentials to lead digital transformation projects
- Building a personal portfolio of MRP improvement case studies
- Life-long access to course materials for ongoing reference
- Understanding the core purpose of MRP in today’s manufacturing landscape
- Evolution from MRP I to MRP II and beyond: What's changed and why it matters
- Key differences between traditional and modern MRP approaches
- Aligning MRP with Lean, Six Sigma, and Industry 4.0 principles
- The role of MRP in preventing overproduction and understocking
- Common myths and misconceptions about Material Requirements Planning
- Defining planning horizons, time fences, and planning cycles
- Understanding the difference between independent and dependent demand
- How MRP fits within ERP, MES, and supply chain ecosystems
- Identifying organisational pain points that MRP can solve
- Recognising early warning signs of an ineffective MRP system
- Overview of the MRP decision-making hierarchy: strategic, tactical, operational
- Introducing the MRP success framework used by leading manufacturers
- Setting realistic, measurable goals for MRP implementation
- Creating stakeholder buy-in and cross-functional alignment
Module 2: Master Data Management for Accurate MRP - The critical role of master data accuracy in MRP reliability
- Ensuring Bill of Materials (BOM) completeness and structure integrity
- Single-level vs. multi-level BOMs: when to use each
- Validating routing data: operation sequences, work centres, and lead times
- Setting and auditing inventory records: on-hand, committed, in-transit
- Managing item master data: part numbers, descriptions, and classifications
- Establishing data governance policies for master file ownership
- Using checklists for regular data health assessments
- Calculating data accuracy KPIs and setting targets
- Correcting common data errors that derail MRP outputs
- Process for regular BOM audits and engineering change order integration
- Handling alternate routings and substitute materials
- Managing phantom assemblies and planning items
- Linking product lifecycle stages to MRP parameters
- Documenting and standardising master data procedures
Module 3: Demand Management & Forecasting for MRP - Integrating sales forecasts into the MRP process
- Distinguishing between forecast-driven and order-driven production
- Choosing the right forecasting method: moving average, exponential smoothing, trend projection
- Qualitative inputs for demand planning: sales team input, market trends
- Using historical data to refine forecast accuracy
- Calculating forecast error metrics: MAPE, MAD, MSE
- Setting safety factors based on forecast volatility
- Incorporating customer-specific contracts and blanket orders
- Managing promotions, campaigns, and seasonal spikes
- Consensus forecasting techniques across sales, marketing, and operations
- Introduction to Sales & Operations Planning (S&OP) alignment
- Setting time-phased demand profiles in the master schedule
- Managing forecast consumption rules
- Updating forecasts dynamically without destabilising MRP
- Best practices for forecast review and adjustment cycles
Module 4: Master Production Scheduling (MPS) Deep Dive - The role of the MPS as the driver of MRP
- Developing a realistic, achievable master production schedule
- Time fencing: demand, planning, and freeze zones
- Setting and communicating the final assembly schedule
- Resolving conflicting priorities between sales and production
- Capacity-checking the MPS using rough-cut capacity planning (RCCP)
- Adjusting the MPS based on resource availability and backlog
- Managing engineering changes mid-schedule
- Handling rush orders and expedited requests
- Prioritisation techniques for order sequencing
- Integrating customer lead time commitments into the MPS
- How the MPS supports order promising and ATP logic
- Running what-if scenarios for schedule adjustments
- Documenting MPS revisions and approvals
- Linking MPS updates to procurement and capacity planning
Module 5: The MRP Engine – Logic, Inputs, and Outputs - Step-by-step walkthrough of MRP calculation logic
- Understanding gross requirements and scheduled receipts
- Calculating projected on-hand inventory over time
- Determining net requirements for each period
- Applying lead time offsetting to generate planned order releases
- Lot sizing techniques: Lot-for-Lot, EOQ, Fixed Order Quantity, Period Order Quantity
- Handling minimum order quantities and supplier constraints
- Understanding time-phased planning and bucketing periods
- Interpreting MRP planned orders, rescheduling notices, and cancellations
- Managing exceptions and alerts in MRP outputs
- Setting action messages and due-date warnings
- Resolving rescheduling suggestions: expedite, delay, cancel
- How MRP interacts with capacity planning systems
- Ensuring MRP runs are properly sequenced and timed
- Validating MRP output against shop floor realities
Module 6: Inventory Management & Optimisation - Principles of inventory types: raw, WIP, finished goods, MRO
- Setting appropriate inventory targets based on demand variability
- Calculating safety stock using statistical methods
- Setting reorder points and order-up-to levels
- Managing cycle counting programs to ensure accuracy
- Reducing obsolete and excess inventory through MRP discipline
- Differentiating between cycle stock, safety stock, and pipeline stock
- Using ABC analysis to prioritise inventory control efforts
- Inventory turnover benchmarks and improvement targets
- Carrying cost calculation and financial impact of inventory decisions
- Linking inventory policy to supplier performance and lead time
- Integrating vendor-managed inventory (VMI) with internal MRP
- Using min/max systems in conjunction with MRP
- Best practices for consignment inventory tracking
- Strategies for reducing inventory without risking service levels
Module 7: Capacity Planning & Load Management - Distinguishing between capacity planning levels: resource planning, RCCP, CRP
- Defining key capacity units: machine hours, labour hours, shifts
- Mapping routings to work centres and capacity models
- Calculating rated capacity vs. demonstrated capacity
- Identifying critical work centres and bottleneck management
- Using finite vs. infinite loading in capacity analysis
- Developing time-phased capacity load reports
- Visualising capacity vs. load using histograms and dashboards
- Resolving capacity constraints: overtime, subcontracting, rescheduling
- Linking CRP outputs to detailed shop floor schedules
- Managing shared resources across multiple product lines
- Planning for maintenance and downtime in capacity models
- Adjusting capacity plans based on MRP-driven requirements
- Using buffer management to absorb variability
- Performance monitoring: utilisation, efficiency, and throughput
Module 8: Procurement & Supplier Integration - Translating MRP outputs into actionable purchase requirements
- Critical path analysis for long-lead items
- Managing supplier lead times and variability
- Creating reliable purchase schedules from planned orders
- Handling make-vs-buy decisions using MRP data
- Integrating blanket orders and contract pricing with MRP
- Synchronising supplier deliveries with production needs
- Managing quality holds and receiving delays in the MRP cycle
- Tracking supplier performance: on-time delivery, quality yield
- Using MRP to support strategic sourcing initiatives
- Preparing for supplier disruptions using safety time buffers
- Managing dual sourcing and alternate vendors in the system
- Aligning procurement cycles with MRP planning buckets
- Handling international logistics and customs delays
- Best practices for purchase order release and follow-up
Module 9: Shop Floor Control & Production Execution - Closing the loop between MRP and actual shop floor activity
- Shop order generation from planned production releases
- Work order documentation and release procedures
- Tracking order progress: started, in process, completed
- Reporting actual material consumption vs. standard BOMs
- Recording actual labour and machine time used
- Managing scrap, rework, and yield variances
- Updating WIP balances and adjusting future MRP runs
- Integrating kitting and material staging with MRP
- Using visual management tools to support MRP execution
- Managing make-to-order, make-to-stock, and engineer-to-order models
- Coordinating with maintenance scheduling for tooling and dies
- Handling rework orders and non-conformance reports
- Updating MRP with actual completion dates
- Using shop floor feedback to refine BOMs and routings
Module 10: Performance Measurement & KPIs - Defining KPIs that reflect MRP system health
- On-time delivery to customer: definition, calculation, tracking
- Inventory accuracy: cycle count adherence and variance rates
- Planned order execution rate and schedule adherence
- MRP system nervousness: causes and reduction strategies
- Forecast accuracy and its impact on MRP stability
- Supplier on-time delivery performance
- Production schedule attainment and bottleneck utilisation
- Scrap and rework rates relative to MRP plans
- Order cycle time from release to completion
- Backlog management and visibility
- Reporting dashboards and executive summary metrics
- Setting baseline, target, and stretch goals for each KPI
- Benchmarking against industry standards
- Using KPIs to drive continuous improvement cycles
Module 11: Advanced MRP Techniques & Edge Cases - Managing remanufacturing and reverse logistics in MRP
- Planning for kits, sets, and configurable products
- Multi-plant MRP: consolidating requirements across locations
- Intercompany transfer planning and material flows
- Co-product and by-product planning
- Handling lot traceability and serialised components
- Regulated environments: MRP for FDA, ISO, or AS9100 compliance
- Planning for product recalls and containment actions
- Managing phased product introductions and end-of-life transitions
- Using MRP for project-based manufacturing
- Planning for service parts and aftermarket demand
- Integrating MRP with drop shipping and 3PL networks
- Managing consignment inventory in the planning system
- Remote work centre scheduling and subcontractor management
- Scenario planning for mergers, plant closures, or relocations
Module 12: MRP & Digital Transformation - How MRP integrates with modern ERP systems like SAP, Oracle, NetSuite
- Leveraging cloud-based MRP platforms for real-time updates
- Using APIs to connect MRP with CRM and supply chain tools
- Automating MRP runs and exception reporting
- Introducing predictive analytics to enhance forecasting
- Using machine learning to identify demand anomalies
- IoT sensors and real-time machine data in capacity planning
- Digital twin applications for MRP simulation and testing
- Barcode and RFID integration for inventory accuracy
- Mobile applications for shop floor data entry and MRP updates
- Integrating MRP with business intelligence and Power BI
- Building custom alerts and dashboards for MRP performance
- Ensuring data security and user access controls
- Change management strategies for digital MRP adoption
- Future trends: AI-driven replenishment and autonomous planning
Module 13: Implementation Roadmap & Change Management - Phased rollout strategy: pilot, transition, full deployment
- Creating a project charter for MRP implementation
- Building a cross-functional implementation team
- Defining roles and responsibilities for MRP ownership
- Conducting readiness assessments and gap analysis
- Developing training programs for planners, buyers, and supervisors
- Running parallel systems during transition period
- Managing resistance to new processes and tools
- Communicating benefits and progress to stakeholders
- Setting up a continuous improvement feedback loop
- Using Kaizen events to refine MRP processes
- Creating standard operating procedures for ongoing management
- Establishing governance and MRP audit processes
- Monitoring adoption rates and user engagement
- Scaling MRP across multiple product lines or divisions
Module 14: Troubleshooting & Sustaining MRP Success - Diagnosing common MRP failures and their root causes
- Fixing “nervous” MRP systems with improper lot sizing
- Resolving data accuracy issues causing planning errors
- Addressing user non-compliance and bypassing of processes
- Reducing excessive rescheduling and system instability
- Managing master data corruption and uncontrolled changes
- Correcting BOM and routing errors in active systems
- Dealing with legacy system limitations and workarounds
- Recovering from inventory count discrepancies
- Handling sudden demand surges or supply disruptions
- Restoring trust in MRP after past failures
- Conducting root cause analysis using 5 Whys and fishbone diagrams
- Using Pareto analysis to prioritise system fixes
- Establishing a monthly MRP health review process
- Building a culture of data integrity and continuous improvement
Module 15: Certification, Next Steps & Career Advancement - Final assessment: evaluating your MRP system design and logic
- Submitting a comprehensive MRP implementation proposal
- Receiving feedback from instructor on your project
- Skills validation and mastery confirmation
- Earning your Certificate of Completion issued by The Art of Service
- Sharing your certification on LinkedIn and job platforms
- Using your MRP expertise in performance reviews and promotions
- Positioning yourself for roles in supply chain leadership
- Networking with other certified manufacturing professionals
- Accessing alumni resources and industry updates
- Continued learning pathways: APICS, CSCP, Lean Master
- Integrating MRP mastery into operational excellence programs
- Using your credentials to lead digital transformation projects
- Building a personal portfolio of MRP improvement case studies
- Life-long access to course materials for ongoing reference
- Integrating sales forecasts into the MRP process
- Distinguishing between forecast-driven and order-driven production
- Choosing the right forecasting method: moving average, exponential smoothing, trend projection
- Qualitative inputs for demand planning: sales team input, market trends
- Using historical data to refine forecast accuracy
- Calculating forecast error metrics: MAPE, MAD, MSE
- Setting safety factors based on forecast volatility
- Incorporating customer-specific contracts and blanket orders
- Managing promotions, campaigns, and seasonal spikes
- Consensus forecasting techniques across sales, marketing, and operations
- Introduction to Sales & Operations Planning (S&OP) alignment
- Setting time-phased demand profiles in the master schedule
- Managing forecast consumption rules
- Updating forecasts dynamically without destabilising MRP
- Best practices for forecast review and adjustment cycles
Module 4: Master Production Scheduling (MPS) Deep Dive - The role of the MPS as the driver of MRP
- Developing a realistic, achievable master production schedule
- Time fencing: demand, planning, and freeze zones
- Setting and communicating the final assembly schedule
- Resolving conflicting priorities between sales and production
- Capacity-checking the MPS using rough-cut capacity planning (RCCP)
- Adjusting the MPS based on resource availability and backlog
- Managing engineering changes mid-schedule
- Handling rush orders and expedited requests
- Prioritisation techniques for order sequencing
- Integrating customer lead time commitments into the MPS
- How the MPS supports order promising and ATP logic
- Running what-if scenarios for schedule adjustments
- Documenting MPS revisions and approvals
- Linking MPS updates to procurement and capacity planning
Module 5: The MRP Engine – Logic, Inputs, and Outputs - Step-by-step walkthrough of MRP calculation logic
- Understanding gross requirements and scheduled receipts
- Calculating projected on-hand inventory over time
- Determining net requirements for each period
- Applying lead time offsetting to generate planned order releases
- Lot sizing techniques: Lot-for-Lot, EOQ, Fixed Order Quantity, Period Order Quantity
- Handling minimum order quantities and supplier constraints
- Understanding time-phased planning and bucketing periods
- Interpreting MRP planned orders, rescheduling notices, and cancellations
- Managing exceptions and alerts in MRP outputs
- Setting action messages and due-date warnings
- Resolving rescheduling suggestions: expedite, delay, cancel
- How MRP interacts with capacity planning systems
- Ensuring MRP runs are properly sequenced and timed
- Validating MRP output against shop floor realities
Module 6: Inventory Management & Optimisation - Principles of inventory types: raw, WIP, finished goods, MRO
- Setting appropriate inventory targets based on demand variability
- Calculating safety stock using statistical methods
- Setting reorder points and order-up-to levels
- Managing cycle counting programs to ensure accuracy
- Reducing obsolete and excess inventory through MRP discipline
- Differentiating between cycle stock, safety stock, and pipeline stock
- Using ABC analysis to prioritise inventory control efforts
- Inventory turnover benchmarks and improvement targets
- Carrying cost calculation and financial impact of inventory decisions
- Linking inventory policy to supplier performance and lead time
- Integrating vendor-managed inventory (VMI) with internal MRP
- Using min/max systems in conjunction with MRP
- Best practices for consignment inventory tracking
- Strategies for reducing inventory without risking service levels
Module 7: Capacity Planning & Load Management - Distinguishing between capacity planning levels: resource planning, RCCP, CRP
- Defining key capacity units: machine hours, labour hours, shifts
- Mapping routings to work centres and capacity models
- Calculating rated capacity vs. demonstrated capacity
- Identifying critical work centres and bottleneck management
- Using finite vs. infinite loading in capacity analysis
- Developing time-phased capacity load reports
- Visualising capacity vs. load using histograms and dashboards
- Resolving capacity constraints: overtime, subcontracting, rescheduling
- Linking CRP outputs to detailed shop floor schedules
- Managing shared resources across multiple product lines
- Planning for maintenance and downtime in capacity models
- Adjusting capacity plans based on MRP-driven requirements
- Using buffer management to absorb variability
- Performance monitoring: utilisation, efficiency, and throughput
Module 8: Procurement & Supplier Integration - Translating MRP outputs into actionable purchase requirements
- Critical path analysis for long-lead items
- Managing supplier lead times and variability
- Creating reliable purchase schedules from planned orders
- Handling make-vs-buy decisions using MRP data
- Integrating blanket orders and contract pricing with MRP
- Synchronising supplier deliveries with production needs
- Managing quality holds and receiving delays in the MRP cycle
- Tracking supplier performance: on-time delivery, quality yield
- Using MRP to support strategic sourcing initiatives
- Preparing for supplier disruptions using safety time buffers
- Managing dual sourcing and alternate vendors in the system
- Aligning procurement cycles with MRP planning buckets
- Handling international logistics and customs delays
- Best practices for purchase order release and follow-up
Module 9: Shop Floor Control & Production Execution - Closing the loop between MRP and actual shop floor activity
- Shop order generation from planned production releases
- Work order documentation and release procedures
- Tracking order progress: started, in process, completed
- Reporting actual material consumption vs. standard BOMs
- Recording actual labour and machine time used
- Managing scrap, rework, and yield variances
- Updating WIP balances and adjusting future MRP runs
- Integrating kitting and material staging with MRP
- Using visual management tools to support MRP execution
- Managing make-to-order, make-to-stock, and engineer-to-order models
- Coordinating with maintenance scheduling for tooling and dies
- Handling rework orders and non-conformance reports
- Updating MRP with actual completion dates
- Using shop floor feedback to refine BOMs and routings
Module 10: Performance Measurement & KPIs - Defining KPIs that reflect MRP system health
- On-time delivery to customer: definition, calculation, tracking
- Inventory accuracy: cycle count adherence and variance rates
- Planned order execution rate and schedule adherence
- MRP system nervousness: causes and reduction strategies
- Forecast accuracy and its impact on MRP stability
- Supplier on-time delivery performance
- Production schedule attainment and bottleneck utilisation
- Scrap and rework rates relative to MRP plans
- Order cycle time from release to completion
- Backlog management and visibility
- Reporting dashboards and executive summary metrics
- Setting baseline, target, and stretch goals for each KPI
- Benchmarking against industry standards
- Using KPIs to drive continuous improvement cycles
Module 11: Advanced MRP Techniques & Edge Cases - Managing remanufacturing and reverse logistics in MRP
- Planning for kits, sets, and configurable products
- Multi-plant MRP: consolidating requirements across locations
- Intercompany transfer planning and material flows
- Co-product and by-product planning
- Handling lot traceability and serialised components
- Regulated environments: MRP for FDA, ISO, or AS9100 compliance
- Planning for product recalls and containment actions
- Managing phased product introductions and end-of-life transitions
- Using MRP for project-based manufacturing
- Planning for service parts and aftermarket demand
- Integrating MRP with drop shipping and 3PL networks
- Managing consignment inventory in the planning system
- Remote work centre scheduling and subcontractor management
- Scenario planning for mergers, plant closures, or relocations
Module 12: MRP & Digital Transformation - How MRP integrates with modern ERP systems like SAP, Oracle, NetSuite
- Leveraging cloud-based MRP platforms for real-time updates
- Using APIs to connect MRP with CRM and supply chain tools
- Automating MRP runs and exception reporting
- Introducing predictive analytics to enhance forecasting
- Using machine learning to identify demand anomalies
- IoT sensors and real-time machine data in capacity planning
- Digital twin applications for MRP simulation and testing
- Barcode and RFID integration for inventory accuracy
- Mobile applications for shop floor data entry and MRP updates
- Integrating MRP with business intelligence and Power BI
- Building custom alerts and dashboards for MRP performance
- Ensuring data security and user access controls
- Change management strategies for digital MRP adoption
- Future trends: AI-driven replenishment and autonomous planning
Module 13: Implementation Roadmap & Change Management - Phased rollout strategy: pilot, transition, full deployment
- Creating a project charter for MRP implementation
- Building a cross-functional implementation team
- Defining roles and responsibilities for MRP ownership
- Conducting readiness assessments and gap analysis
- Developing training programs for planners, buyers, and supervisors
- Running parallel systems during transition period
- Managing resistance to new processes and tools
- Communicating benefits and progress to stakeholders
- Setting up a continuous improvement feedback loop
- Using Kaizen events to refine MRP processes
- Creating standard operating procedures for ongoing management
- Establishing governance and MRP audit processes
- Monitoring adoption rates and user engagement
- Scaling MRP across multiple product lines or divisions
Module 14: Troubleshooting & Sustaining MRP Success - Diagnosing common MRP failures and their root causes
- Fixing “nervous” MRP systems with improper lot sizing
- Resolving data accuracy issues causing planning errors
- Addressing user non-compliance and bypassing of processes
- Reducing excessive rescheduling and system instability
- Managing master data corruption and uncontrolled changes
- Correcting BOM and routing errors in active systems
- Dealing with legacy system limitations and workarounds
- Recovering from inventory count discrepancies
- Handling sudden demand surges or supply disruptions
- Restoring trust in MRP after past failures
- Conducting root cause analysis using 5 Whys and fishbone diagrams
- Using Pareto analysis to prioritise system fixes
- Establishing a monthly MRP health review process
- Building a culture of data integrity and continuous improvement
Module 15: Certification, Next Steps & Career Advancement - Final assessment: evaluating your MRP system design and logic
- Submitting a comprehensive MRP implementation proposal
- Receiving feedback from instructor on your project
- Skills validation and mastery confirmation
- Earning your Certificate of Completion issued by The Art of Service
- Sharing your certification on LinkedIn and job platforms
- Using your MRP expertise in performance reviews and promotions
- Positioning yourself for roles in supply chain leadership
- Networking with other certified manufacturing professionals
- Accessing alumni resources and industry updates
- Continued learning pathways: APICS, CSCP, Lean Master
- Integrating MRP mastery into operational excellence programs
- Using your credentials to lead digital transformation projects
- Building a personal portfolio of MRP improvement case studies
- Life-long access to course materials for ongoing reference
- Step-by-step walkthrough of MRP calculation logic
- Understanding gross requirements and scheduled receipts
- Calculating projected on-hand inventory over time
- Determining net requirements for each period
- Applying lead time offsetting to generate planned order releases
- Lot sizing techniques: Lot-for-Lot, EOQ, Fixed Order Quantity, Period Order Quantity
- Handling minimum order quantities and supplier constraints
- Understanding time-phased planning and bucketing periods
- Interpreting MRP planned orders, rescheduling notices, and cancellations
- Managing exceptions and alerts in MRP outputs
- Setting action messages and due-date warnings
- Resolving rescheduling suggestions: expedite, delay, cancel
- How MRP interacts with capacity planning systems
- Ensuring MRP runs are properly sequenced and timed
- Validating MRP output against shop floor realities
Module 6: Inventory Management & Optimisation - Principles of inventory types: raw, WIP, finished goods, MRO
- Setting appropriate inventory targets based on demand variability
- Calculating safety stock using statistical methods
- Setting reorder points and order-up-to levels
- Managing cycle counting programs to ensure accuracy
- Reducing obsolete and excess inventory through MRP discipline
- Differentiating between cycle stock, safety stock, and pipeline stock
- Using ABC analysis to prioritise inventory control efforts
- Inventory turnover benchmarks and improvement targets
- Carrying cost calculation and financial impact of inventory decisions
- Linking inventory policy to supplier performance and lead time
- Integrating vendor-managed inventory (VMI) with internal MRP
- Using min/max systems in conjunction with MRP
- Best practices for consignment inventory tracking
- Strategies for reducing inventory without risking service levels
Module 7: Capacity Planning & Load Management - Distinguishing between capacity planning levels: resource planning, RCCP, CRP
- Defining key capacity units: machine hours, labour hours, shifts
- Mapping routings to work centres and capacity models
- Calculating rated capacity vs. demonstrated capacity
- Identifying critical work centres and bottleneck management
- Using finite vs. infinite loading in capacity analysis
- Developing time-phased capacity load reports
- Visualising capacity vs. load using histograms and dashboards
- Resolving capacity constraints: overtime, subcontracting, rescheduling
- Linking CRP outputs to detailed shop floor schedules
- Managing shared resources across multiple product lines
- Planning for maintenance and downtime in capacity models
- Adjusting capacity plans based on MRP-driven requirements
- Using buffer management to absorb variability
- Performance monitoring: utilisation, efficiency, and throughput
Module 8: Procurement & Supplier Integration - Translating MRP outputs into actionable purchase requirements
- Critical path analysis for long-lead items
- Managing supplier lead times and variability
- Creating reliable purchase schedules from planned orders
- Handling make-vs-buy decisions using MRP data
- Integrating blanket orders and contract pricing with MRP
- Synchronising supplier deliveries with production needs
- Managing quality holds and receiving delays in the MRP cycle
- Tracking supplier performance: on-time delivery, quality yield
- Using MRP to support strategic sourcing initiatives
- Preparing for supplier disruptions using safety time buffers
- Managing dual sourcing and alternate vendors in the system
- Aligning procurement cycles with MRP planning buckets
- Handling international logistics and customs delays
- Best practices for purchase order release and follow-up
Module 9: Shop Floor Control & Production Execution - Closing the loop between MRP and actual shop floor activity
- Shop order generation from planned production releases
- Work order documentation and release procedures
- Tracking order progress: started, in process, completed
- Reporting actual material consumption vs. standard BOMs
- Recording actual labour and machine time used
- Managing scrap, rework, and yield variances
- Updating WIP balances and adjusting future MRP runs
- Integrating kitting and material staging with MRP
- Using visual management tools to support MRP execution
- Managing make-to-order, make-to-stock, and engineer-to-order models
- Coordinating with maintenance scheduling for tooling and dies
- Handling rework orders and non-conformance reports
- Updating MRP with actual completion dates
- Using shop floor feedback to refine BOMs and routings
Module 10: Performance Measurement & KPIs - Defining KPIs that reflect MRP system health
- On-time delivery to customer: definition, calculation, tracking
- Inventory accuracy: cycle count adherence and variance rates
- Planned order execution rate and schedule adherence
- MRP system nervousness: causes and reduction strategies
- Forecast accuracy and its impact on MRP stability
- Supplier on-time delivery performance
- Production schedule attainment and bottleneck utilisation
- Scrap and rework rates relative to MRP plans
- Order cycle time from release to completion
- Backlog management and visibility
- Reporting dashboards and executive summary metrics
- Setting baseline, target, and stretch goals for each KPI
- Benchmarking against industry standards
- Using KPIs to drive continuous improvement cycles
Module 11: Advanced MRP Techniques & Edge Cases - Managing remanufacturing and reverse logistics in MRP
- Planning for kits, sets, and configurable products
- Multi-plant MRP: consolidating requirements across locations
- Intercompany transfer planning and material flows
- Co-product and by-product planning
- Handling lot traceability and serialised components
- Regulated environments: MRP for FDA, ISO, or AS9100 compliance
- Planning for product recalls and containment actions
- Managing phased product introductions and end-of-life transitions
- Using MRP for project-based manufacturing
- Planning for service parts and aftermarket demand
- Integrating MRP with drop shipping and 3PL networks
- Managing consignment inventory in the planning system
- Remote work centre scheduling and subcontractor management
- Scenario planning for mergers, plant closures, or relocations
Module 12: MRP & Digital Transformation - How MRP integrates with modern ERP systems like SAP, Oracle, NetSuite
- Leveraging cloud-based MRP platforms for real-time updates
- Using APIs to connect MRP with CRM and supply chain tools
- Automating MRP runs and exception reporting
- Introducing predictive analytics to enhance forecasting
- Using machine learning to identify demand anomalies
- IoT sensors and real-time machine data in capacity planning
- Digital twin applications for MRP simulation and testing
- Barcode and RFID integration for inventory accuracy
- Mobile applications for shop floor data entry and MRP updates
- Integrating MRP with business intelligence and Power BI
- Building custom alerts and dashboards for MRP performance
- Ensuring data security and user access controls
- Change management strategies for digital MRP adoption
- Future trends: AI-driven replenishment and autonomous planning
Module 13: Implementation Roadmap & Change Management - Phased rollout strategy: pilot, transition, full deployment
- Creating a project charter for MRP implementation
- Building a cross-functional implementation team
- Defining roles and responsibilities for MRP ownership
- Conducting readiness assessments and gap analysis
- Developing training programs for planners, buyers, and supervisors
- Running parallel systems during transition period
- Managing resistance to new processes and tools
- Communicating benefits and progress to stakeholders
- Setting up a continuous improvement feedback loop
- Using Kaizen events to refine MRP processes
- Creating standard operating procedures for ongoing management
- Establishing governance and MRP audit processes
- Monitoring adoption rates and user engagement
- Scaling MRP across multiple product lines or divisions
Module 14: Troubleshooting & Sustaining MRP Success - Diagnosing common MRP failures and their root causes
- Fixing “nervous” MRP systems with improper lot sizing
- Resolving data accuracy issues causing planning errors
- Addressing user non-compliance and bypassing of processes
- Reducing excessive rescheduling and system instability
- Managing master data corruption and uncontrolled changes
- Correcting BOM and routing errors in active systems
- Dealing with legacy system limitations and workarounds
- Recovering from inventory count discrepancies
- Handling sudden demand surges or supply disruptions
- Restoring trust in MRP after past failures
- Conducting root cause analysis using 5 Whys and fishbone diagrams
- Using Pareto analysis to prioritise system fixes
- Establishing a monthly MRP health review process
- Building a culture of data integrity and continuous improvement
Module 15: Certification, Next Steps & Career Advancement - Final assessment: evaluating your MRP system design and logic
- Submitting a comprehensive MRP implementation proposal
- Receiving feedback from instructor on your project
- Skills validation and mastery confirmation
- Earning your Certificate of Completion issued by The Art of Service
- Sharing your certification on LinkedIn and job platforms
- Using your MRP expertise in performance reviews and promotions
- Positioning yourself for roles in supply chain leadership
- Networking with other certified manufacturing professionals
- Accessing alumni resources and industry updates
- Continued learning pathways: APICS, CSCP, Lean Master
- Integrating MRP mastery into operational excellence programs
- Using your credentials to lead digital transformation projects
- Building a personal portfolio of MRP improvement case studies
- Life-long access to course materials for ongoing reference
- Distinguishing between capacity planning levels: resource planning, RCCP, CRP
- Defining key capacity units: machine hours, labour hours, shifts
- Mapping routings to work centres and capacity models
- Calculating rated capacity vs. demonstrated capacity
- Identifying critical work centres and bottleneck management
- Using finite vs. infinite loading in capacity analysis
- Developing time-phased capacity load reports
- Visualising capacity vs. load using histograms and dashboards
- Resolving capacity constraints: overtime, subcontracting, rescheduling
- Linking CRP outputs to detailed shop floor schedules
- Managing shared resources across multiple product lines
- Planning for maintenance and downtime in capacity models
- Adjusting capacity plans based on MRP-driven requirements
- Using buffer management to absorb variability
- Performance monitoring: utilisation, efficiency, and throughput
Module 8: Procurement & Supplier Integration - Translating MRP outputs into actionable purchase requirements
- Critical path analysis for long-lead items
- Managing supplier lead times and variability
- Creating reliable purchase schedules from planned orders
- Handling make-vs-buy decisions using MRP data
- Integrating blanket orders and contract pricing with MRP
- Synchronising supplier deliveries with production needs
- Managing quality holds and receiving delays in the MRP cycle
- Tracking supplier performance: on-time delivery, quality yield
- Using MRP to support strategic sourcing initiatives
- Preparing for supplier disruptions using safety time buffers
- Managing dual sourcing and alternate vendors in the system
- Aligning procurement cycles with MRP planning buckets
- Handling international logistics and customs delays
- Best practices for purchase order release and follow-up
Module 9: Shop Floor Control & Production Execution - Closing the loop between MRP and actual shop floor activity
- Shop order generation from planned production releases
- Work order documentation and release procedures
- Tracking order progress: started, in process, completed
- Reporting actual material consumption vs. standard BOMs
- Recording actual labour and machine time used
- Managing scrap, rework, and yield variances
- Updating WIP balances and adjusting future MRP runs
- Integrating kitting and material staging with MRP
- Using visual management tools to support MRP execution
- Managing make-to-order, make-to-stock, and engineer-to-order models
- Coordinating with maintenance scheduling for tooling and dies
- Handling rework orders and non-conformance reports
- Updating MRP with actual completion dates
- Using shop floor feedback to refine BOMs and routings
Module 10: Performance Measurement & KPIs - Defining KPIs that reflect MRP system health
- On-time delivery to customer: definition, calculation, tracking
- Inventory accuracy: cycle count adherence and variance rates
- Planned order execution rate and schedule adherence
- MRP system nervousness: causes and reduction strategies
- Forecast accuracy and its impact on MRP stability
- Supplier on-time delivery performance
- Production schedule attainment and bottleneck utilisation
- Scrap and rework rates relative to MRP plans
- Order cycle time from release to completion
- Backlog management and visibility
- Reporting dashboards and executive summary metrics
- Setting baseline, target, and stretch goals for each KPI
- Benchmarking against industry standards
- Using KPIs to drive continuous improvement cycles
Module 11: Advanced MRP Techniques & Edge Cases - Managing remanufacturing and reverse logistics in MRP
- Planning for kits, sets, and configurable products
- Multi-plant MRP: consolidating requirements across locations
- Intercompany transfer planning and material flows
- Co-product and by-product planning
- Handling lot traceability and serialised components
- Regulated environments: MRP for FDA, ISO, or AS9100 compliance
- Planning for product recalls and containment actions
- Managing phased product introductions and end-of-life transitions
- Using MRP for project-based manufacturing
- Planning for service parts and aftermarket demand
- Integrating MRP with drop shipping and 3PL networks
- Managing consignment inventory in the planning system
- Remote work centre scheduling and subcontractor management
- Scenario planning for mergers, plant closures, or relocations
Module 12: MRP & Digital Transformation - How MRP integrates with modern ERP systems like SAP, Oracle, NetSuite
- Leveraging cloud-based MRP platforms for real-time updates
- Using APIs to connect MRP with CRM and supply chain tools
- Automating MRP runs and exception reporting
- Introducing predictive analytics to enhance forecasting
- Using machine learning to identify demand anomalies
- IoT sensors and real-time machine data in capacity planning
- Digital twin applications for MRP simulation and testing
- Barcode and RFID integration for inventory accuracy
- Mobile applications for shop floor data entry and MRP updates
- Integrating MRP with business intelligence and Power BI
- Building custom alerts and dashboards for MRP performance
- Ensuring data security and user access controls
- Change management strategies for digital MRP adoption
- Future trends: AI-driven replenishment and autonomous planning
Module 13: Implementation Roadmap & Change Management - Phased rollout strategy: pilot, transition, full deployment
- Creating a project charter for MRP implementation
- Building a cross-functional implementation team
- Defining roles and responsibilities for MRP ownership
- Conducting readiness assessments and gap analysis
- Developing training programs for planners, buyers, and supervisors
- Running parallel systems during transition period
- Managing resistance to new processes and tools
- Communicating benefits and progress to stakeholders
- Setting up a continuous improvement feedback loop
- Using Kaizen events to refine MRP processes
- Creating standard operating procedures for ongoing management
- Establishing governance and MRP audit processes
- Monitoring adoption rates and user engagement
- Scaling MRP across multiple product lines or divisions
Module 14: Troubleshooting & Sustaining MRP Success - Diagnosing common MRP failures and their root causes
- Fixing “nervous” MRP systems with improper lot sizing
- Resolving data accuracy issues causing planning errors
- Addressing user non-compliance and bypassing of processes
- Reducing excessive rescheduling and system instability
- Managing master data corruption and uncontrolled changes
- Correcting BOM and routing errors in active systems
- Dealing with legacy system limitations and workarounds
- Recovering from inventory count discrepancies
- Handling sudden demand surges or supply disruptions
- Restoring trust in MRP after past failures
- Conducting root cause analysis using 5 Whys and fishbone diagrams
- Using Pareto analysis to prioritise system fixes
- Establishing a monthly MRP health review process
- Building a culture of data integrity and continuous improvement
Module 15: Certification, Next Steps & Career Advancement - Final assessment: evaluating your MRP system design and logic
- Submitting a comprehensive MRP implementation proposal
- Receiving feedback from instructor on your project
- Skills validation and mastery confirmation
- Earning your Certificate of Completion issued by The Art of Service
- Sharing your certification on LinkedIn and job platforms
- Using your MRP expertise in performance reviews and promotions
- Positioning yourself for roles in supply chain leadership
- Networking with other certified manufacturing professionals
- Accessing alumni resources and industry updates
- Continued learning pathways: APICS, CSCP, Lean Master
- Integrating MRP mastery into operational excellence programs
- Using your credentials to lead digital transformation projects
- Building a personal portfolio of MRP improvement case studies
- Life-long access to course materials for ongoing reference
- Closing the loop between MRP and actual shop floor activity
- Shop order generation from planned production releases
- Work order documentation and release procedures
- Tracking order progress: started, in process, completed
- Reporting actual material consumption vs. standard BOMs
- Recording actual labour and machine time used
- Managing scrap, rework, and yield variances
- Updating WIP balances and adjusting future MRP runs
- Integrating kitting and material staging with MRP
- Using visual management tools to support MRP execution
- Managing make-to-order, make-to-stock, and engineer-to-order models
- Coordinating with maintenance scheduling for tooling and dies
- Handling rework orders and non-conformance reports
- Updating MRP with actual completion dates
- Using shop floor feedback to refine BOMs and routings
Module 10: Performance Measurement & KPIs - Defining KPIs that reflect MRP system health
- On-time delivery to customer: definition, calculation, tracking
- Inventory accuracy: cycle count adherence and variance rates
- Planned order execution rate and schedule adherence
- MRP system nervousness: causes and reduction strategies
- Forecast accuracy and its impact on MRP stability
- Supplier on-time delivery performance
- Production schedule attainment and bottleneck utilisation
- Scrap and rework rates relative to MRP plans
- Order cycle time from release to completion
- Backlog management and visibility
- Reporting dashboards and executive summary metrics
- Setting baseline, target, and stretch goals for each KPI
- Benchmarking against industry standards
- Using KPIs to drive continuous improvement cycles
Module 11: Advanced MRP Techniques & Edge Cases - Managing remanufacturing and reverse logistics in MRP
- Planning for kits, sets, and configurable products
- Multi-plant MRP: consolidating requirements across locations
- Intercompany transfer planning and material flows
- Co-product and by-product planning
- Handling lot traceability and serialised components
- Regulated environments: MRP for FDA, ISO, or AS9100 compliance
- Planning for product recalls and containment actions
- Managing phased product introductions and end-of-life transitions
- Using MRP for project-based manufacturing
- Planning for service parts and aftermarket demand
- Integrating MRP with drop shipping and 3PL networks
- Managing consignment inventory in the planning system
- Remote work centre scheduling and subcontractor management
- Scenario planning for mergers, plant closures, or relocations
Module 12: MRP & Digital Transformation - How MRP integrates with modern ERP systems like SAP, Oracle, NetSuite
- Leveraging cloud-based MRP platforms for real-time updates
- Using APIs to connect MRP with CRM and supply chain tools
- Automating MRP runs and exception reporting
- Introducing predictive analytics to enhance forecasting
- Using machine learning to identify demand anomalies
- IoT sensors and real-time machine data in capacity planning
- Digital twin applications for MRP simulation and testing
- Barcode and RFID integration for inventory accuracy
- Mobile applications for shop floor data entry and MRP updates
- Integrating MRP with business intelligence and Power BI
- Building custom alerts and dashboards for MRP performance
- Ensuring data security and user access controls
- Change management strategies for digital MRP adoption
- Future trends: AI-driven replenishment and autonomous planning
Module 13: Implementation Roadmap & Change Management - Phased rollout strategy: pilot, transition, full deployment
- Creating a project charter for MRP implementation
- Building a cross-functional implementation team
- Defining roles and responsibilities for MRP ownership
- Conducting readiness assessments and gap analysis
- Developing training programs for planners, buyers, and supervisors
- Running parallel systems during transition period
- Managing resistance to new processes and tools
- Communicating benefits and progress to stakeholders
- Setting up a continuous improvement feedback loop
- Using Kaizen events to refine MRP processes
- Creating standard operating procedures for ongoing management
- Establishing governance and MRP audit processes
- Monitoring adoption rates and user engagement
- Scaling MRP across multiple product lines or divisions
Module 14: Troubleshooting & Sustaining MRP Success - Diagnosing common MRP failures and their root causes
- Fixing “nervous” MRP systems with improper lot sizing
- Resolving data accuracy issues causing planning errors
- Addressing user non-compliance and bypassing of processes
- Reducing excessive rescheduling and system instability
- Managing master data corruption and uncontrolled changes
- Correcting BOM and routing errors in active systems
- Dealing with legacy system limitations and workarounds
- Recovering from inventory count discrepancies
- Handling sudden demand surges or supply disruptions
- Restoring trust in MRP after past failures
- Conducting root cause analysis using 5 Whys and fishbone diagrams
- Using Pareto analysis to prioritise system fixes
- Establishing a monthly MRP health review process
- Building a culture of data integrity and continuous improvement
Module 15: Certification, Next Steps & Career Advancement - Final assessment: evaluating your MRP system design and logic
- Submitting a comprehensive MRP implementation proposal
- Receiving feedback from instructor on your project
- Skills validation and mastery confirmation
- Earning your Certificate of Completion issued by The Art of Service
- Sharing your certification on LinkedIn and job platforms
- Using your MRP expertise in performance reviews and promotions
- Positioning yourself for roles in supply chain leadership
- Networking with other certified manufacturing professionals
- Accessing alumni resources and industry updates
- Continued learning pathways: APICS, CSCP, Lean Master
- Integrating MRP mastery into operational excellence programs
- Using your credentials to lead digital transformation projects
- Building a personal portfolio of MRP improvement case studies
- Life-long access to course materials for ongoing reference
- Managing remanufacturing and reverse logistics in MRP
- Planning for kits, sets, and configurable products
- Multi-plant MRP: consolidating requirements across locations
- Intercompany transfer planning and material flows
- Co-product and by-product planning
- Handling lot traceability and serialised components
- Regulated environments: MRP for FDA, ISO, or AS9100 compliance
- Planning for product recalls and containment actions
- Managing phased product introductions and end-of-life transitions
- Using MRP for project-based manufacturing
- Planning for service parts and aftermarket demand
- Integrating MRP with drop shipping and 3PL networks
- Managing consignment inventory in the planning system
- Remote work centre scheduling and subcontractor management
- Scenario planning for mergers, plant closures, or relocations
Module 12: MRP & Digital Transformation - How MRP integrates with modern ERP systems like SAP, Oracle, NetSuite
- Leveraging cloud-based MRP platforms for real-time updates
- Using APIs to connect MRP with CRM and supply chain tools
- Automating MRP runs and exception reporting
- Introducing predictive analytics to enhance forecasting
- Using machine learning to identify demand anomalies
- IoT sensors and real-time machine data in capacity planning
- Digital twin applications for MRP simulation and testing
- Barcode and RFID integration for inventory accuracy
- Mobile applications for shop floor data entry and MRP updates
- Integrating MRP with business intelligence and Power BI
- Building custom alerts and dashboards for MRP performance
- Ensuring data security and user access controls
- Change management strategies for digital MRP adoption
- Future trends: AI-driven replenishment and autonomous planning
Module 13: Implementation Roadmap & Change Management - Phased rollout strategy: pilot, transition, full deployment
- Creating a project charter for MRP implementation
- Building a cross-functional implementation team
- Defining roles and responsibilities for MRP ownership
- Conducting readiness assessments and gap analysis
- Developing training programs for planners, buyers, and supervisors
- Running parallel systems during transition period
- Managing resistance to new processes and tools
- Communicating benefits and progress to stakeholders
- Setting up a continuous improvement feedback loop
- Using Kaizen events to refine MRP processes
- Creating standard operating procedures for ongoing management
- Establishing governance and MRP audit processes
- Monitoring adoption rates and user engagement
- Scaling MRP across multiple product lines or divisions
Module 14: Troubleshooting & Sustaining MRP Success - Diagnosing common MRP failures and their root causes
- Fixing “nervous” MRP systems with improper lot sizing
- Resolving data accuracy issues causing planning errors
- Addressing user non-compliance and bypassing of processes
- Reducing excessive rescheduling and system instability
- Managing master data corruption and uncontrolled changes
- Correcting BOM and routing errors in active systems
- Dealing with legacy system limitations and workarounds
- Recovering from inventory count discrepancies
- Handling sudden demand surges or supply disruptions
- Restoring trust in MRP after past failures
- Conducting root cause analysis using 5 Whys and fishbone diagrams
- Using Pareto analysis to prioritise system fixes
- Establishing a monthly MRP health review process
- Building a culture of data integrity and continuous improvement
Module 15: Certification, Next Steps & Career Advancement - Final assessment: evaluating your MRP system design and logic
- Submitting a comprehensive MRP implementation proposal
- Receiving feedback from instructor on your project
- Skills validation and mastery confirmation
- Earning your Certificate of Completion issued by The Art of Service
- Sharing your certification on LinkedIn and job platforms
- Using your MRP expertise in performance reviews and promotions
- Positioning yourself for roles in supply chain leadership
- Networking with other certified manufacturing professionals
- Accessing alumni resources and industry updates
- Continued learning pathways: APICS, CSCP, Lean Master
- Integrating MRP mastery into operational excellence programs
- Using your credentials to lead digital transformation projects
- Building a personal portfolio of MRP improvement case studies
- Life-long access to course materials for ongoing reference
- Phased rollout strategy: pilot, transition, full deployment
- Creating a project charter for MRP implementation
- Building a cross-functional implementation team
- Defining roles and responsibilities for MRP ownership
- Conducting readiness assessments and gap analysis
- Developing training programs for planners, buyers, and supervisors
- Running parallel systems during transition period
- Managing resistance to new processes and tools
- Communicating benefits and progress to stakeholders
- Setting up a continuous improvement feedback loop
- Using Kaizen events to refine MRP processes
- Creating standard operating procedures for ongoing management
- Establishing governance and MRP audit processes
- Monitoring adoption rates and user engagement
- Scaling MRP across multiple product lines or divisions
Module 14: Troubleshooting & Sustaining MRP Success - Diagnosing common MRP failures and their root causes
- Fixing “nervous” MRP systems with improper lot sizing
- Resolving data accuracy issues causing planning errors
- Addressing user non-compliance and bypassing of processes
- Reducing excessive rescheduling and system instability
- Managing master data corruption and uncontrolled changes
- Correcting BOM and routing errors in active systems
- Dealing with legacy system limitations and workarounds
- Recovering from inventory count discrepancies
- Handling sudden demand surges or supply disruptions
- Restoring trust in MRP after past failures
- Conducting root cause analysis using 5 Whys and fishbone diagrams
- Using Pareto analysis to prioritise system fixes
- Establishing a monthly MRP health review process
- Building a culture of data integrity and continuous improvement
Module 15: Certification, Next Steps & Career Advancement - Final assessment: evaluating your MRP system design and logic
- Submitting a comprehensive MRP implementation proposal
- Receiving feedback from instructor on your project
- Skills validation and mastery confirmation
- Earning your Certificate of Completion issued by The Art of Service
- Sharing your certification on LinkedIn and job platforms
- Using your MRP expertise in performance reviews and promotions
- Positioning yourself for roles in supply chain leadership
- Networking with other certified manufacturing professionals
- Accessing alumni resources and industry updates
- Continued learning pathways: APICS, CSCP, Lean Master
- Integrating MRP mastery into operational excellence programs
- Using your credentials to lead digital transformation projects
- Building a personal portfolio of MRP improvement case studies
- Life-long access to course materials for ongoing reference
- Final assessment: evaluating your MRP system design and logic
- Submitting a comprehensive MRP implementation proposal
- Receiving feedback from instructor on your project
- Skills validation and mastery confirmation
- Earning your Certificate of Completion issued by The Art of Service
- Sharing your certification on LinkedIn and job platforms
- Using your MRP expertise in performance reviews and promotions
- Positioning yourself for roles in supply chain leadership
- Networking with other certified manufacturing professionals
- Accessing alumni resources and industry updates
- Continued learning pathways: APICS, CSCP, Lean Master
- Integrating MRP mastery into operational excellence programs
- Using your credentials to lead digital transformation projects
- Building a personal portfolio of MRP improvement case studies
- Life-long access to course materials for ongoing reference