Citation: Malindzakova, M.; Garaj, P.;
Trpˇcevská, J.; Malindzak, D. Setting
MRP Parameters and Optimizing the
Production Planning Process.
Processes 2022, 10, 690. https://
doi.org/10.3390/pr10040690
Academic Editors: Arkadiusz Gola,
Izabela Nielsen and Patrik Grznár
Received: 13 March 2022
Accepted: 30 March 2022
Published: 1 April 2022
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Article
Setting MRP Parameters and Optimizing the Production
Planning Process
Marcela Malindzakova
1,
*, Patrik Garaj
1
, Jarmila Trpˇcevská
2
and Dusan Malindzak
3
1
Faculty of Mining, Ecology, Process Control and Geotechnologies, Institute of Logistics and Transport,
Technical University of Kosice, 042 00 Kosice, Slovakia; garajpatrik4@gmail.com
2
Faculty of Materials, Metallurgy and Recycling, Institute of Recycling Technologies,
Technical University of Kosice, 042 00 Kosice, Slovakia; jarmila.trpcevska@tuke.sk
3
Consultant, U. S. STELL Kosice s. r. o., Vstupny Areal U. S. STEEL, 044 54 Kosice, Slovakia;
dmalindzak@gmail.com
* Correspondence: marcela.malindzakova@tuke.sk; Tel.: +421-55-602-3158
Abstract:
This article describes a methodical framework that combines two specific methods of Lean
management, namely the ABC method and the MRP planning method. The article further argues that
combining the ABC inventory method with subsequent MRP planning is beneficial if the combination
is implemented in practice. To demonstrate the benefits, the framework is tested using a case study
company. The presented case-study problem is to reduce the number of changeover downtimes
in the environment of an engineering production company. The researched company deals with
the problem of setting up production lines in a way to minimize the number of downtimes within
one work shift. Within the solution, four possible variants of the production plan are presented. By
combining the ABC and MRP methods, up to four changeovers can be saved, which in financial
terms represents a saving of about EUR 450,000 per year.
Keywords:
Lean management; Material Resources Planning (MRP); ABC inventory analysis;
optimization; planning
1. Introduction
In the current climate of constant change in the market, inventory management
becomes a serious issue requiring systematic planning, monitoring and control.
Because large companies produce several hundred different types of products each, it
is a daunting task to effectively maintain control over the storage and handling processes
of components. This article wishes to propose a combination of methods to tackle this
inventory problem, namely the ABC inventory analysis method and the MRP method
(Material Resources Planning). To date, several approaches have been suggested to deal
with the inventory issue by involving ABC analysis. The inventory concepts and advantages
of ABC classification were analyzed and the method’s various steps were implemented
using ABC analysis to analyze an original case discussed by [
1
]. Kumar [
2
] suggested that
the inventory problem in compressor manufacturing can be evaluated and understood
using inventory management and ABC analysis.
Kavitha [
3
] proposed the performance of ABC analysis in order to determine the effec-
tiveness of inventory management in a manufacturing company in the area of agricultural
machine production. Similar research was conducted by [
4
] to analyze a case study on the
efficiency of the ABC analysis of inventory management in a giant warehouse. Asana [
5
]
proposed stock control methods using ABC analysis and MinMax analysis. The approach
was implemented in a retail management information system. Additionally, Ref. [
6
] ex-
plored the effectiveness of using a reorder point (ROP) automated system in combination
with inventory control using the ABC analysis method within a textile industry company.
Processes 2022, 10, 690. https://doi.org/10.3390/pr10040690 https://www.mdpi.com/journal/processes
