Production Planning and Material Requirements Software

The software starts with production schedules showing what finished products to make and when. It breaks down each product into components, sub-assemblies, and raw materials required through all levels of the product structure. The system checks current inventory and materials already on order, then calculates net requirements showing exactly what needs purchasing or manufacturing. It automatically generates purchase requisitions and production orders timed properly for when materials are needed.

Yes, the software calculates which materials are needed for upcoming production and when they must arrive. It compares requirements against current inventory and incoming orders to identify potential shortages before production starts. Automated alerts notify purchasing teams when materials need ordering. You see lead times for critical components and can order early enough to prevent production delays from missing materials.

Capacity analysis calculates equipment time and labor hours required for planned production at each station. It compares required capacity versus available capacity accounting for shifts, maintenance schedules, and current workload. This identifies where capacity is insufficient, which stations become bottlenecks limiting production, and whether you can realistically meet planned schedules. You can adjust plans or add resources before capacity constraints cause missed deliveries.

Production scheduling determines what finished products to manufacture and when production should happen based on customer orders and inventory needs. Material planning calculates which components and raw materials are required for that production schedule, when they're needed, and generates purchase orders. Scheduling decides 'what to make,' material planning ensures 'we have materials to make it.' Both work together for effective production planning.

The software processes products with multiple levels automatically—finished products contain sub-assemblies, which contain components, which require raw materials. It calculates requirements through all levels accounting for how long each step takes. Materials needed early in production get scheduled earlier than items needed at final assembly. Complex product structures with hundreds of components get processed accurately without manual calculation.

Yes, planning software connects with purchasing to create purchase requisitions automatically when materials are needed. It links with inventory to check current stock levels and incoming orders before calculating net requirements. When materials arrive, inventory updates and planning sees increased availability instantly. Purchase orders, inventory movements, and production requirements all stay synchronized automatically without manual data entry between systems.

Planning horizon depends on supplier lead times and production complexity. If materials take weeks to arrive, plan production at least that far ahead to order materials on time. Most manufacturers plan 4-12 weeks ahead with detailed schedules for near-term production and rough plans for longer periods. Update plans regularly as customer orders change, inventory fluctuates, and capacity constraints become clearer.

Material requirements recalculate when production schedules change. If production increases, the system shows additional materials needed and when to order them. If production decreases or delays, it identifies materials that can be postponed or canceled. Capacity analysis updates to show new equipment and labor requirements. All planning elements adjust together maintaining synchronization between schedules, materials, and capacity.

NetSuite and Dynamics 365 provide material planning and scheduling with features like demand forecasting, advanced scheduling algorithms, and supply chain analytics. Alpide's advantage is production planning that works seamlessly with the entire manufacturing system—material requirements flow directly to purchasing, capacity constraints update production schedules, and inventory changes recalculate material needs instantly. For growing manufacturers needing planning that actually connects with daily operations, Alpide eliminates manual data entry between planning and execution at substantially lower cost.

Production planning is the broader process of determining what to make, ensuring materials are available, and verifying capacity. Production scheduling is the specific activity of assigning when each production job runs on which equipment. Planning provides the overall strategy, scheduling creates the detailed execution timeline.

Safety stock is extra inventory kept to prevent stockouts from demand spikes or supply delays. Material planning maintains safety stock levels when calculating requirements. If inventory plus incoming orders fall below safety stock thresholds, the system generates orders to replenish buffers even without immediate production needs.

Yes, plan production for custom customer orders requiring specific configurations alongside standard products manufactured for inventory. The system schedules both types, calculates materials for each, and checks capacity for combined workload. Allocate factory resources between immediate customer orders and building stock inventory.

Update expected delivery dates in the system to reflect actual supplier commitments. Material planning shows which production jobs are affected by late materials. Capacity analysis shows freed-up capacity from delayed jobs. Reschedule production to match actual material availability or find alternate suppliers urgently.

Create production schedules that build inventory during slow periods for anticipated busy seasons. Balance manufacturing throughout the year to smooth capacity utilization even when demand fluctuates. Calculate total materials needed for entire seasonal cycle to negotiate better supplier pricing on larger volumes.