MRP runs and exceptions

Production Planner needs to explain the planning window before the team acts on a result. Each MRP run keeps a run number, as-of date, horizon end and assigned planner. Setting a run to Running starts planning against eligible customer demand and the stock and dated supply available to cover it.

The exception review connects an issue to its run and item. The planner checks whether the problem concerns a shortage, past-due supply or engineering inputs requiring investigation. Keep the customer need and the source evidence available while deciding what must change before the plan can be accepted.

• Make the window explicit. Production Planner checks the as-of date and horizon end before starting. The default horizon ends thirty days after the as-of date. Review the dates actually used when comparing planning attempts.
• Check the supply basis. Review on-hand less reserved stock, dated open production and outstanding purchasing quantities. Existing suggestions marked Proposed or Firmed contribute to the supply review so repeated planning considers coverage already proposed.
• Separate correction from approval. Production Planner and Production Operator investigate exceptions. Assign Manager’s plan approval responsibility during setup and prepare the run for that decision only after the quantities and dates have been checked.

Agree who starts a run, who investigates an unexpected result and how the team handles a run marked Failed. Rehearse the workflow with a small demand population the planner can reconcile. Inspect the completed attempt before moving the operating review forward, and keep failed attempts available for follow-up.

Decide how the team retains the explanation behind a resolved exception. Review the source correction before entering a resolution date. For engineering-related issues, agree the connection to the engineering or planning source and name the person who supplies the required evidence. Include that owner in the first exception rehearsal.

Use an Approved order inside the horizon, a later approved order outside it and a Draft order inside it. Production Planner checks the included demand before discussing the suggested quantity. Add a partly received purchase and open production with a planned end date so the review covers incoming quantities and timing.

Repeat planning while earlier suggestions remain Proposed or Firmed. Compare coverage with the original attempt and investigate any extra quantity. Check whether stock, customer dates or supplier commitments changed between attempts before attributing a difference to the run itself.

Next, review an exception concerning missing lead-time information with the planning source owner. Check that evidence and reassess the affected requirement. Manager reviews the run when it reaches Review and records the approval decision under the responsibility agreed during setup. Keep unexplained shortages in the review until their owners can account for them.

• MRP run review — Runs at Review with their planning window and assigned planner visible.
• My MRP runs — Planning work assigned to the signed-in person’s staff record.
• MRP run board — The run lifecycle, with Failed attempts retained for investigation.

Follow Demand to MRP review, then Exception investigation for issues requiring correction.