Multi-level BOM calculations
Expand finished-goods demand into subassembly and component requirements across BOM levels.
Material requirements planning
MRP Software for Smarter Material Planning
Know what components you need, how many are available, and when to replenish them. Sonic Fusion X turns production demand into a practical material plan.
- BOM explosion
- Shortage analysis
- Lead-time planning
- Replenishment
Material requirements planning
Plan the right materials for the right production date
Translate finished-product demand into component requirements, compare those requirements with supply, and identify the net shortages that need action.
Available material review
Consider the current inventory position, reserved material, and expected supply as part of netting.
Supplier lead-time planning
Factor expected lead times into when materials should be ordered or expedited.
Shortage analysis
Focus attention on components that cannot satisfy planned demand.
Planned replenishment
Use the shortage review to support purchase requisitions or purchasing actions.
Plan revision
Reassess requirements when quantities, due dates, or supply assumptions change.
Planning example
Example: material planning for 100 assemblies
This sample highlights why order quantities alone do not reveal what needs to be purchased.
Illustrative workflow
Component shortages for a 100-unit order
The planned 100 assemblies require four screws, two panels, and one cable each.
| Material | Quantity required | Usable on hand | Scheduled receipts | Net shortage |
|---|---|---|---|---|
| Screws | 400 | 240 | 100 | 60 |
| Panels | 200 | 175 | 0 | 25 |
| Cables | 100 | 120 | 0 | 0 |
Illustrative calculation assumes no other reservations, scrap allowance, or minimum order quantities.
Net requirements
When MRP catches a shortage
The planning team can use exceptions to make decisions before material constraints interrupt production.
- 01
Confirm planned demand
Check required production quantities and dates.
- 02
Expand the BOM
Calculate components needed across the assemblies.
- 03
Net available supply
Consider stock that is usable and expected on-time receipts.
- 04
Review shortages
Prioritize items with a negative projected balance.
- 05
Plan purchasing
Review vendors, lead times, minimum order quantities, and approval rules.
Connected purchasing
Make purchasing and manufacturing work together
A clear materials plan supports timely purchasing without relying on disconnected spreadsheets.
Material requirements planning is most useful when production requirements and purchasing decisions are evaluated together. A revised production date may change when a component is needed. An overdue supplier delivery may require an alternate purchasing decision.
Sonic Fusion X connects MRP planning with purchasing and production data to help teams work from a consistent picture of material needs.
Explore manufacturing ERPSee how BOMs and production orders fit together.Common questions
Frequently Asked Questions
Answers to common questions about mrp software.
What is MRP software?
Material requirements planning software calculates the materials needed to support production demand, accounting for BOM quantities and available supply.
What is a net material requirement?
It is the remaining required quantity after accounting for usable inventory and qualifying planned receipts.
Does MRP replace purchasing approvals?
No. MRP identifies needs; purchasing and company authorization rules determine which orders are released.
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