Orlicky´s Material Requirements Planning

Chad Smith and Carol Ptak


Level of TOC knowledge acquired:

Introductory and Intermediate


546 pages

Designed for:

Consultants, Implementers, Managers and Shop Floor workers


Distribution and Supply Chain


Buffer Management and Pull System/Replenishment




Hardcover and Download



The classic MRP work up-to-date with new information on supply chain synchronization

Thoroughly revised, Orlicky´s Materials Requirements Planning, Third Edition reviews the poor business results embedded in most of todays business systems; discusses the core problems causing the results; presents and discusses an alternative pull structure for planning and controlling materials flow; and presents initial results from actual implementations. This new edition reveals the next evolutionary step for materials and supply chain synchronization in the modern manufacturing landscape. This update describes:

  • A solution to a chronic MRP-related problem that plagues many manufacturers: shortages of materials, components that block the smooth flow of work through the plant
  • A competitive edge through strategic lead time reductions
  • Significant reductions in total inventory investment
  • Significant increases in service levels

This new edition helps companies tackle three pervasive problems: unacceptable inventory performance; unacceptable service level performance; and high related expenses and waste.

New to This Edition:

  • New section on manufacturing as the heart of the supply chain management, and specific challenges in the 21st century
  • Covers supply chain management (SCM) and distribution requirements planning (DRP)
  • Discusses the impact of Lean and the Toyota Production System
  • Update of integration software
  • Reviews the emergence of demand-driven strategies and the MRP “conflict”
  • Introduces the new concept of ASR (Actively Synchronized Replenishment) and explains how to incorporate it into business processes
  • Explains positioning and how Six Sigma can help achieve results
  • In-depth discussion of buffers – how to size, maintain, and adjust them
  • New chapter on using MRP tools across the supply chain to enable pull-based approaches
  • New case studies which illustrating the techniques described in the book

Comprehensive coverage:
The Whole and Its Parts; Manufacturing as a Process; Inventory Management; Prerequisites of MRP 3.0; Traditional Methodology; MRP Logic; Keeping MRP Up to Date; Lot Sizing and Safety Stock; Data Requirements and Management; MRP 3.0; Traditional MRP in Today’s Environment; MRP 3.0 Component 1—Strategic Inventory Positioning; Component 2—Buffer Level Profiling; Component 3—Dynamic Buffer Maintenance; Component 4—Pull-Based Demand Generation; Component 5—Highly Visible and Collaborative Execution; Dynamic Buffer Level Profiling; ASR Demand Generation; Applications; Developing Valid Inputs; Making Outputs Useful; Demand Driven Philosophies and MRP; Engineer to Order Environments; Lessons of the Past; Present State; The Future of MRP 3.0



  • Perspective
  • Concepts
  • Managing with the MRP System
  • Looking Backwards and Forward