1. Manufacturing Systems MRP Tutorial 2
Developed by:
Alex J. Ruiz-Torres, Ph.D.

2. Objectives/ Structure
This tutorial will illustrate all the steps required to develop a multiple item MRP schedule.
MRP tables
Production Plan
It is assumed that the student already reviewed and has a good understanding of the concepts presented in
MRP Tutorial 1

3. Product Information and Requirements
Develop an MRP schedule and final production plan Two End Items (Two End Products)
Large unit
Small unit
Tpaste
(14 oz)
Tpaste
(8 oz)
Pack-l (1)
Cap (1)
Pack-s (1)
Cap (1)
Both End products use the same Tpaste and the same Cap.

4. Product Information and Requirements
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000
Demand/ Requirements
Large unit
Week 10 = 190
Week 11 = 120
Week 12 = 780
Small unit
Week 9 = 250
Week 11 = 425
Week 12 = 200

5. MRP Table for the parent items (2)
Demand/
Requirements
Week 10 = 190
Week 11 = 120
Week 12 = 780
Large 6 7 8 9 10 11 12 13 GR
190
120
780 OH
330
210 NR 70
570 PR
400 PE
Large
From Tutorial 1
The production release for Large unit is as follows:
Large 6 7 8 9 10 11 12 13 PE
400
570

6. MRP Table for the parent items (2)
Demand/
Requirements
Week 9 = 250
Week 11 = 425
Week 12 = 200
Small 6 7 8 9 10 11 12 13 GR
250
425
200 OH NR PR PE
Small unit
The demand requirements are the GR

7. MRP Table for the parent items (2)
Small 6 7 8 9 10 11 12 13 GR
250
425
200 OH
310 NR PR PE
Current week = 6
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000
The initial OH from the table goes
into the first week as OH
The OH carries over until the
first week with a GR

8. MRP Table for the parent items (2)
Small 6 7 8 9 10 11 12 13 GR
250
425
200 OH
310 60 NR PR PE
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000
NR = 0 as the OH > GR
OH next period
= PR + OH – GR
= – 250 = 60

9. MRP Table for the parent items (2)
Small 6 7 8 9 10 11 12 13 GR
250
425
200 OH
310 60 NR
365 PR
500 PE
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000
NR = GR – OH = 425 – 60 = 365
to determine the PR
The minimum is 500 therefore
PR = 500
PE = PR moved one week

10. MRP Table for the parent items (2)
Small 6 7 8 9 10 11 12 13 GR
250
425
200 OH
310 60
135 NR
365 65 PR
500 PE
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000
OH next period
= PR + OH – GR
= – 425 = 135
NR = GR – OH = 65

11. MRP Table for the parent items (2)
Small 6 7 8 9 10 11 12 13 GR
250
425
200 OH
310 60
135
435 NR
365 65 PR
500 PE
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000
to determine the PR
The minimum is 500 therefore
PR = 500.
PE = PR moved one week
OH = PR + OH – GR =
= – 200 = 435

12. MRP Table for the parent items (2)
Demand/
Requirements
Week 9 = 250
Week 11 = 425
Week 12 = 200
Small 6 7 8 9 10 11 12 13 GR
250
425
200 OH
310 60
135
435 NR
365 65 PR
500 PE
Small unit
The production release for Small unit is as follows:
Small 6 7 8 9 10 11 12 13 PE
500

13. The process is repeated
MRP Tables must be completed for all components.
At this time could do any of the four.
Will do Pack-s
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000
Pack-s (1)

14. MRP Table for the Pack-s
Demand for Pack-s depends on its parent item (Small unit)
So based on the PE (planned releases) of the parent item
Relationship: 1 Pack-s per 1 Small unit
parent
Small 6 7 8 9 10 11 12 13 PE
500
Pack-s 6 7 8 9 10 11 12 13 GR
500 OH NR PR PE

15. MRP Table for the Pack-s
Small 6 7 8 9 10 11 12 13 GR
500 OH NR PR PE
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000
The initial OH from the table goes into the first week as OH
OH carries over until the first week with a GR
NR = GR – OH = 500
PR = NR as there is no minimum or lot size
PE is the same as the PR offset by the lead time

16. MRP Table for the Pack-s
Small 6 7 8 9 10 11 12 13 GR
500 OH NR PR PE
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000
OH next period =
GR – PR – OH = 500 – 500 – 0 = 0
Rest is the same as in the previous week.

17. MRP Table for the Pack-s
Small 6 7 8 9 10 11 12 13 GR
500 OH NR PR PE
The completed MRP table for the Pack-s
The production release for Pack-s is as follows:
Pack-s 6 7 8 9 10 11 12 13 PE
500

18. MRP Table for the Pack-l6 7 8 9 10 11 12 13 GR
400
570 OH
340 90
120 NR 60
480 PR
150
600 PE
The completed MRP table for Pack-l
From Tutorial 1
The production release for Pack-l is as follows:
Pack-l 6 7 8 9 10 11 12 13 PE
150
600

19. MRP Table for Cap
This is an item (component) that has multiple parents.
Therefore it must be based on the production releases of all its “parents” simultaneously.

20. MRP Table for Cap Large 6 7 8 9 10 11 12 13 Small 6 7 8 9 10 11 12 13PE
400
570
Small 6 7 8 9 10 11 12 13 PE
500
One Cap per Large One Cap per Small
Cap 6 7 8 9 10 11 12 13 GR
400
500
1,070 OH NR PR PE

21. MRP Table for Cap
Cap 6 7 8 9 10 11 12 13 GR
400
500
1,070 OH NR PR PE
OH starts at 0. Given there is no lot size or minimum the PR = NR. PE = PR offset by one week
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000

22. MRP Table for Cap
Cap 6 7 8 9 10 11 12 13 GR
400
500
1,070 OH NR PR PE
The completed MRP table for the Cap
The production release for Cap is as follows (with demand from the 2 end items):
Cap 6 7 8 9 10 11 12 13 PE
400
500
1,070

23. MRP Table for Tpaste
This is an item (component) that has multiple parents.
Therefore it must be based on the production releases of all its “parents” simultaneously.

24. MRP Table for Tpaste This is in ounces
Large 6 7 8 9 10 11 12 13 PE
400
570
14 ounces per Large unit 8 ounces per Small unit
Small 6 7 8 9 10 11 12 13 PE
500
570 x 14 +
500 x 8
400 x 14
500 x 8
Tpaste 6 7 8 9 10 11 12 13 GR
5,600
4,000
11,980 OH NR PR PE
This is in
ounces

25. MRP Table for the Tpaste6 7 8 9 10 11 12 13 GR
5,600
4,000
11,980 OH
970 NR
4,630 PR
6,000 PE
OH starts at 970. PR is based on a LS = 3,000 Need two lots to satisfy the NR PR = 6,000 PE = PR offset by one week
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000

26. MRP Table for the Tpaste6 7 8 9 10 11 12 13 GR
5,600
4,000
11,980 OH
970
1,370 NR
4,630
2,630 PR
6,000
3,000 PE
OH next week OH + PR – GR = 1,370. PR is based on a LS = 3,000 Need 1 lot to satisfy the NR PR = 3,000 PE = PR offset by one week
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000

27. MRP Table for the Tpaste6 7 8 9 10 11 12 13 GR
5,600
4,000
11,980 OH
970
1,370
370
390 NR
4,630
2,630
11,610 PR
6,000
3,000
12,000 PE
OH next week (week 11) OH + PR – GR = 1, ,000 – 4,000 =370. PR is based on a LS = 3,000 Need 4 lots to satisfy the NR. PR = 12,000 PE = PR offset by one week OH next week (week 12) OH + PR – GR = ,000 – 11,980 = 390.
Item OH LT
Lot Size or Min.
Large unit
120 1
M = 400
Small unit
310
M = 500
Pack-l
340 2
LS = 150
Pack-s
None
Cap
Tpaste
970
LS = 3,000

28. MRP Table for the Tpaste6 7 8 9 10 11 12 13 GR
5,600
4,000
11,980 OH
970
1,370
370
390 NR
4,630
2,630
11,610 PR
6,000
3,000
12,000 PE
The completed MRP table for Tpaste
The production release for Tpaste is as follows (with demand from the 2 end items): :
Tpaste 6 7 8 9 10 11 12 13 PE
6,000
3,000
12,000

29. Production Plan
These are the release schedules of production as to meet the customer demand.
PEs 6 7 8 9 10 11 12 13
Large
400
570
Small
500
Pack-l
150
600
Pack-s
500
Cap
400
570
Tpaste
6,000
3,000
12,000