Material requirements planning process
Editable material requirements planning process swimlane from “Load demand and bill of materials” through “Inventory and demand data reliable?” to a documented outcome. Includes named roles, exception paths and evidence.
What the material requirements planning process process is
The workflow starts at “Load demand and bill of materials”. The next two steps, “Check on-hand stock and open receipts” and “Apply lead time, safety stock and lot rules”, establish the information needed for a defensible decision. The chart assigns each handoff to a role and retains the evidence at closeout.
The main gates are “Inventory and demand data reliable?” and “Recommended quantity and date feasible?”. The first branch leads to correct stock, bom or forecast inputs; the second can require rephase build or source alternate material. Tune lead times and safety stock to actual variability and criticality.
What this flowchart covers
In this template
- Load demand and bill of materials followed by check on-hand stock and open receipts.
- Inventory and demand data reliable? with a route for correct stock, bom or forecast inputs.
- Calculate net material requirement and review shortages, excess and substitutions as separate supplier and internal handoffs.
- Recommended quantity and date feasible? with rephase build or source alternate material when the decision fails.
- Release purchase recommendation to buyer, confirm po dates with supplier and record plan assumptions and exception actions as the controlled closeout.
When to use this template
- Use it to agree who owns “Load demand and bill of materials” and what information the next role needs.
- Use it when the answer to “Inventory and demand data reliable?” is unclear or decisions are made outside the record.
- Use it to make “Record plan assumptions and exception actions” visible in an audit or operational review.
How it works
Assign decision owners
Replace the Planning, Warehouse, Production, Buyer, Supplier lanes with your actual functions. Keep the owner of “Inventory and demand data reliable?” separate from the requester where your authority rules require it.
Configure the gates
Tune lead times and safety stock to actual variability and criticality. Define what evidence is sufficient for “Recommended quantity and date feasible?” and who may authorize an exception.
Connect downstream records
Link record plan assumptions and exception actions to the relevant purchase order, contract, supplier record or operational case. Set retention and review dates under your document policy.
Frequently asked questions
What does the material requirements planning process template include?
It covers load demand and bill of materials, apply lead time, safety stock and lot rules, review shortages, excess and substitutions, and record plan assumptions and exception actions, with two labelled decisions and rework paths.
Can the decision rules be changed?
Yes. Tune lead times and safety stock to actual variability and criticality. Edit the gate labels, swimlanes and return paths before using the chart in your organization.
What evidence should be retained?
Keep the input to “Inventory and demand data reliable?”, the evidence behind “Recommended quantity and date feasible?”, approvals or exception decisions, and the closeout record: “Record plan assumptions and exception actions”.
Where this process fits
In most operations this process follows Supply planning process.
Comes before
- Supply planning process — Editable supply planning process swimlane from “Collect sales forecast and firm orders” through “Supply covers priority demand?” to a documented outcome. Includes named roles, exception paths and evidence.