Planning & MRP

Planning & MRP — Every Sales Order Becomes a Material Plan

FOS explodes each sales order against its BOM, runs MRP, reserves stock and raises exactly the work orders and purchases you need — with shortages flagged before they hit the floor.

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Order to plan in one run · Feeds Production & Purchase

AutoSO → WO + PRMRP driven

6WOs raisedFrom SO-4821

2ShortagesPR created

480Parts reservedFrom stock

Station timeline

Cutting & nestingDone · 4h 12m
Complete
Welding — Station BIn progress · 62%
Running
Galvanising — SubconIssued 1.2 T
Awaiting

Exceptions

2 open

WO-4819Material short
Blocked
Paint boothQueue 2 WOs
Delay

Subcontract jobs

Galv batch WB-1181.2 T issued
In transit
Machining lot 44Due Fri
Scheduled

22% Lower inventory
1 run Order to plan
92% On-time dispatch
0 Surprise shortages

Why teams switch

You have the orders. You just can't plan them.

Planning isn't another spreadsheet. It's one MRP run from sales order to work orders, purchases and a date you can promise.

Walk through the product

01
Plans on last week's stock
MRP runs against stale counts — so the plan is wrong before it starts.
02
Shortages on the shop floor
Material gaps discovered mid-job — not when MRP could have flagged them.
03
Purchase reqs raised too late
Buyers scramble after the shortage — not when lead time still allows.
04
Promise dates that are guesses
Customers get dates from optimism — not capacity and material reality.
05
Production runs blind
The floor executes against a plan nobody trusts — and replans every week.

Product walkthrough

Three moments. One committed plan.

From sales order to work orders, purchases and a promise date the whole plant can run on.

NetBOM · Stock · Demand

ScheduleCapacity · Promise dates

ControlShortages · Requisitions

Explode & net

One run, every requirement.

MRP reserves available stock, raises work orders, and flags shortages as purchase requisitions — before they ever reach the floor.

BOM explosion to the last leaf
Automatic stock reservation
Shortages → purchase requisitions

MRP run · SO-4821

WOChassis weld assemblyWork order raised · qty 6Planned

PRIS Angle 65×65 · 1.2 TShortage → purchase reqShortage

STM16 fasteners · 480 pcsReserved from stockReserved

SO → work orders + POsAuto

Schedule

Promise dates you can keep.

FOS schedules work orders against real capacity and material availability — so every order gets a date grounded in reality, not optimism.

Capacity-aware scheduling
Material-constrained dates
Balanced station load

1Demand netted
Stock + open orders

2Capacity check
Station load balanced

3Work orders scheduled
Promised 14 Jul

4Shortages flagged
2 → purchase

Promised dateReliable

Stay ahead

See shortages before they bite.

A live shortage view shows exactly what would stall which order — with lead times attached — so you act early, not at the last minute.

Live shortage dashboard
Lead-time aware
Drill to the order at risk

Shortage view

12Open work orders

3Live shortages

₹18 LPR value

5 daysAvg lead time

Netted acrossAll BOM levels

Connected platform

Plans flow straight into Production & Purchase

Work orders hit the shop floor. Shortages become purchase requisitions. No re-keying between modules.

CRM & Sales Sales orders in Explore module

Planning & MRP SO → BOM → plan You are here

Production Work orders out Explore module

Purchase Requisitions raised Explore module

Capability map

Everything planning needs — in one engine

BOMs, MRP, capacity and shortage control — one connected planning core.

BOM managementMulti-level, alternate, revisions

MRP engineNet requirements, reservation

Capacity planningWork centres, load view

Production planOrder-wise, promise dates

Shortage managementLive shortages, auto PR

Demand forecastHistory, seasonality

Our MRP used to take two planners a full day every week. Now one run nets every order — and shortages show up days before they hit welding, not during it.

Executive briefing

Plan every order with confidence.

A focused 30-minute walkthrough of MRP, scheduling and shortage control — mapped to your BOMs and shop-floor reality.

Live in ~6 weeks
Industry-specific scope
Response in 1 business day

Book executive briefing +91 9328850777

What planning capabilities does FOS provide?

FOS planning includes demand management, MRP, capacity visibility, and production scheduling for discrete manufacturers. It explodes BOMs, suggests purchase and work orders, and highlights shortages before they stop the line.

Does FOS support multi-level BOM MRP?

Yes. Multi-level BOM explosion handles assemblies, sub-assemblies, purchased parts, and phantom items. MRP respects lead times, safety stock, and order policies to generate actionable purchase and production proposals.

How does FOS handle make vs buy decisions?

MRP distinguishes manufactured and purchased items, generating work orders for in-house production and purchase requisitions for bought-out parts. Subcontract operations appear as planned orders with material issue requirements.

Can planners see capacity constraints?

Planners view load against work centres and calendars, identifying overloads before releasing orders. Finite scheduling options help sequence jobs at bottleneck operations common in fabrication and machining plants.

What MRP exception reports are available?

Standard exceptions include shortages, excess stock, rescheduled orders, and past-due supply. Planners action exceptions daily instead of discovering material gaps on the shop floor.

Does planning support batch and lot sizing rules?

FOS supports fixed lot, lot-for-lot, minimum order quantities, and order multiples per item. These rules reflect how you buy plate, castings, or standard components from vendors.

How are sales order changes reflected in MRP?

Order quantity or date changes regenerate dependent demand and rescheduled supply suggestions. Planners see impact on procurement and production immediately rather than after manual spreadsheet updates.

Can we plan across multiple warehouses?

Multi-warehouse MRP considers stock at each location, transfers, and site-specific lead times. Central planning teams coordinate material for plants that share common purchased parts.

Is rough-cut capacity planning included?

Rough-cut and detailed capacity views help align master schedule with available hours at welding, machining, or assembly centres. This prevents accepting orders the plant cannot build on time.

How long does it take to stabilise MRP after go-live?

Most plants run weekly MRP cycles within the first month after master data cleanup. FOS implementation includes BOM and inventory validation so the first MRP run produces trustworthy proposals.