How to Optimize Material Requirements Planning (MRP) in Epicor

Overview

Material Requirements Planning (MRP) is one of the most important modules in Epicor Kinetic. MRP evaluates supply, demand, inventory, jobs, purchase orders, forecasts, and lead times to generate purchasing and production recommendations. When configured correctly, MRP helps manufacturers maintain inventory availability while minimizing excess stock. For custom inventory analysis, developers often create tailored BAQ reports to track real-time stock balances. For technical discussions and answers, visit the EpiUsers

Many MRP issues are not caused by the MRP engine itself but by inaccurate planning data. Incorrect lead times, outdated part settings, poor BOM maintenance, and inconsistent scheduling practices often result in excessive suggestions, shortages, and planner frustration.

Maintain Accurate Lead Times

Lead times are among the most critical inputs for MRP calculations. Epicor uses purchasing lead times, manufacturing lead times, setup times, and production times when determining material requirements and scheduling recommendations. Inaccurate lead times can create unrealistic purchase suggestions and job schedules.

Review lead times regularly for:

• Purchased components
• Manufactured parts
• Subassemblies
• Supplier-specific items
• Long-lead materials

Review Planning Time Fences

Planning Time Fences can significantly impact MRP recommendations. Improperly configured time fences may cause MRP to generate unexpected replenishment suggestions or delay scheduling changes. Many Epicor users discover planning issues after go-live because MRP is honoring time fence rules that planners were not expecting.

Regularly review:

• Planning Time Fence settings
• Demand Time Fence settings
• Locked jobs and schedules
• Firm jobs and purchase orders

Clean Up Part Planning Parameters

MRP performs best when part planning parameters are maintained consistently. Safety stock, minimum quantities, order multiples, lot sizes, and replenishment methods should be reviewed periodically to ensure they reflect current business requirements. Poor master data often leads to unnecessary recommendations and inventory imbalances.

Monitor MRP Suggestions

Purchase, job, and transfer suggestions provide valuable insight into planning performance. Large numbers of expedite, postpone, or cancel suggestions may indicate issues with lead times, supplier performance, scheduling practices, or inventory policies. Regular analysis of suggestions helps planners identify root causes before they become larger operational problems.

Validate Bills of Material and Routings

MRP calculations rely heavily on engineering data. Incorrect Bills of Material (BOMs), operation standards, quantities per assembly, and routing information can create inaccurate material demand and unrealistic schedules.

• Verify BOM accuracy.
• Review operation times.
• Validate setup and production standards.
• Remove obsolete components.
• Audit engineering changes regularly.

Use MRP Diagnostics and Planning Reports

Epicor provides multiple tools for analyzing planning results, including Time Phase, MRP reports, and planning diagnostics. These tools help planners understand why recommendations are being generated and identify the supply-and-demand relationships driving MRP decisions. Experienced Epicor users often rely on Time Phase as one of the primary troubleshooting tools when investigating planning issues. If you need to automate notifications or actions when supply levels drop, you can configure a custom BPM workflow.

MRP Optimization Checklist

• ✓ Review lead times regularly
• ✓ Validate Planning Time Fence settings
• ✓ Audit safety stock levels
• ✓ Maintain accurate BOMs and routings
• ✓ Analyze expedite and cancel suggestions
• ✓ Review supplier performance
• ✓ Monitor inventory accuracy
• ✓ Use Time Phase for troubleshooting
• ✓ Remove obsolete planning data
• ✓ Train planners on MRP behavior