Ostendo MRP & Replenishment

Material Requirements Planning (MRP) & Replenishment in Ostendo Continuum ERP

Overview

Material Requirements Planning (MRP) in Ostendo Continuum provides a powerful, data-driven framework for ensuring the right materials are available at the right time, while minimising excess inventory and working capital.

Ostendo’s MRP and replenishment capabilities combine real-time demand, historical usage, forecasting, and lead-time intelligence to automatically generate purchase orders and production orders—supporting manufacturing, distribution, and hybrid businesses with complex supply chains.

What is MRP in Ostendo Continuum?

MRP in Ostendo determines what to buy or make, how much, and when, based on both current and anticipated demand. It continuously evaluates inventory availability against:

  • Sales orders and backorders
  • Production and job requirements
  • Forecast demand
  • Reorder levels and minimum quantities
  • Lead times and days of stock

The result is a clear, projected view of inventory availability that supports proactive planning rather than reactive purchasing. 

Core MRP Capabilities

Inventory Forecasting and Usage History

Ostendo can report on historical inventory usage to calculate forecast demand, supporting smarter replenishment decisions—especially for fast-moving or seasonal items. 

Reorder Levels & Minimum Quantities

Each item can be configured with:

  • Minimum stock quantities
  • Reorder levels
  • Lead times

These settings allow replenishment rules to reflect real-world supplier and production constraints. 

Projected Availability by Date & Priority

Ostendo evaluates inventory availability by required date, taking into account:

  • Sales orders
  • Jobs and production orders
  • Order priority
  • Existing commitments

This ensures scarce stock is allocated where it delivers the greatest business value. 

Replenishment & Order Creation

Purchase & Production Orders

When MRP identifies a shortfall, Ostendo can:

  • Suggest purchase orders
  • Suggest production orders
  • Link orders directly to the originating demand

This reduces manual intervention, improves accuracy, and shortens planning cycles. 

Source-on-Demand Items

For items configured as source on demand, Ostendo can generate purchasing or manufacturing requirements directly linked to the source record, ensuring full traceability from demand to supply. 

Multi-Level Production Planning

Ostendo’s MRP engine supports multi-level production orders, exploding Bills of Materials (BOMs) through all levels and linking them back to a single sales requirement.

This is particularly powerful for:

  • Complex assemblies
  • Make-to-order manufacturing
  • Engineer-to-order workflows

All dependent production and purchasing activity remains synchronised and traceable. 

Distribution & Quote-to-Cash Alignment

MRP and replenishment in Ostendo integrate seamlessly with the Quote-to-Cash lifecycle, ensuring inventory availability supports quoting, order fulfilment, and customer service commitments.

This alignment ensures:

  • Accurate delivery promises
  • Reduced stock-outs
  • Faster order turnaround
  • Improved customer satisfaction 

Kanban Two-Bin Replenishment

Ostendo also supports Kanban Two-Bin replenishment, providing a simple but effective method for managing consumables and fast-moving items with short lead times where forecast precision is less critical but availability is essential. 

Why Ostendo MRP Delivers Business Value

With Ostendo Continuum, MRP is not a standalone calculation—it is embedded into daily operations, delivering:

  • Lower inventory holding costs
  • Reduced expediting and firefighting
  • Improved production efficiency
  • Better supplier coordination
  • Data-driven planning confidence

For organisations seeking scalable, practical MRP without ERP complexity overload, Ostendo provides a uniquely balanced solution.

Reporting & Analysis

Effective material planning depends on clear, real-time visibility across demand, supply, and stock positions. Within Ostendo Continuum, reporting and visibility tools for Material Requirements & Replenishment provide planners, buyers, and operations teams with the insight they need to avoid shortages, reduce excess inventory, and maintain uninterrupted production and service delivery.

End-to-End Material Visibility

Ostendo delivers a single source of truth for material demand and supply, combining sales orders, jobs, forecasts, BOM demand, and current inventory into actionable views. Users can instantly see:

  • Net material requirements by item, warehouse, or time period
  • On-hand, allocated, on-order, and available quantities
  • Shortages and future stock-out risks before they impact operations

This end-to-end transparency supports proactive planning rather than reactive purchasing.

Demand-Driven Replenishment Insights

Material requirements reporting dynamically reflects real operational demand, including:

  • Job, project, and manufacturing order requirements
  • Sales order and forecast-driven demand
  • Safety stock and reorder point breaches

Replenishment dashboards highlight what needs to be purchased or produced, when it is required, and in what quantity—supporting smarter purchasing decisions and improved supplier coordination.

Purchase Planning & Supplier Performance Reporting

Replenishment visibility extends beyond internal demand to purchasing and supplier execution:

  • Planned vs actual purchase orders
  • Supplier lead time performance and delivery reliability
  • Price variance and cost trend analysis

These insights help procurement teams optimise supplier selection, negotiate better terms, and reduce material cost volatility.

Inventory Optimisation & Working Capital Control

Material reporting supports continuous improvement by identifying:

  • Excess, slow-moving, and obsolete stock
  • Overstock risks caused by forecast changes or demand drops
  • Opportunities to rebalance inventory across locations

By aligning replenishment to real demand, businesses can reduce working capital tied up in inventory while maintaining service levels.

Exception-Based Management & Alerts

Rather than reviewing static reports, Ostendo enables exception-based visibility:

  • Items below safety stock or reorder point
  • Late or incomplete supplier deliveries
  • Material shortages threatening jobs or production schedules

This allows planners and buyers to focus attention where it matters most.

Strategic Insight for Planning & Growth

Material requirements and replenishment reporting supports both operational and strategic decisions, including:

  • Capacity and supply chain planning
  • Make-to-order vs make-to-stock evaluation
  • Scenario analysis for demand changes or supplier disruptions

With accurate, real-time insight into materials, organisations gain confidence in their planning, improve service reliability, and build a more resilient supply chain.

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