Production demand
Define the number of finished goods needed and the planned production date.
Material requirements planning
MRP Software for BOMs, Material Shortages and Replenishment
Know what components you need, what supply is available and when to buy more. Sonic Fusion X links production demand and bills of materials to material planning and purchasing decisions.
Six connected steps
Turn a production order into a usable material plan
MRP helps identify the net component requirement rather than assuming the entire gross requirement must be purchased.
BOM explosion
Multiply production quantities by each component’s quantity per assembly.
Usable stock
Compare requirements with inventory available for the job.
Explore solutionScheduled receipts
Include qualifying supplier or production receipts that arrive by the need date.
Net shortages
Calculate material gaps and focus purchasing reviews on those exceptions.
Replenishment planning
Review lead times, supplier terms, minimum quantities and approvals.
Explore solutionWorked material plan
100-unit production order: which components are short?
Assume each finished assembly requires 4 screws, 2 panels and 1 cable. The example compares gross demand to inventory and receipts.
| Component | Per assembly | Gross required | Usable stock | On-time receipts | Net shortage |
|---|---|---|---|---|---|
| Screws | 4 | 400 | 240 | 100 | 60 |
| Panels | 2 | 200 | 175 | 0 | 25 |
| Cables | 1 | 100 | 120 | 0 | 0 |
MRP calculationNet shortage = max(0, gross requirements − usable stock − on-time receipts)
Screws: 400 − 240 − 100 = 60 to replenish. Panels: 200 − 175 = 25. Cables: 100 − 120 is below zero, so the shortage is zero.
Illustrative simplified example. Reservations, scrap, yield, safety stock, inventory status, lead times and order policies can change actual requirements.
Planning ahead
The quantity is only part of the answer
An MRP plan becomes actionable when timing, reservations and supplier decisions are considered.
- 01
Confirm the production date
An item needed Tuesday cannot necessarily be covered by a delivery scheduled Friday.
- 02
Check relevant open supply
Only count receipts that are approved, appropriate and expected by the needed date.
- 03
Review vendor lead times
Account for manufacturing, transit and receiving time when planning purchase release dates.
- 04
Re-run when plans change
Recalculate if demand, receipts, inventory or dates are revised.
Sample requirements versus usable supply
Screws require planned replenishment
Illustrative example only; not customer performance data.
Straight answers
Frequently asked questions
Practical answers about how the software fits into day-to-day operations.
What does MRP software calculate?
MRP uses demand, approved BOM quantities, available inventory and expected supply to calculate material requirements and shortages.
Does MRP replace production scheduling?
No. It supports scheduling by identifying materials needed and timing risks; detailed scheduling and execution are related processes.
How does BOM explosion work?
BOM explosion expands a finished-product quantity into the required components and, for multi-level BOMs, into subassemblies and lower-level materials.