How do planners respond when the replenishment signal changes?

A new MRP proposal, shortage, excess, late receipt, or capacity conflict is a decision signal. The planner must distinguish a genuine policy change from a one-off exception before changing supply.

THE DECISION

Change demand, supply, or the planning rule?

Forecast, safety stock, lot size, lead time, firmed supply, capacity, and inventory each own a different part of the result. Replanning should make the decision visible rather than silently overriding the next MRP run.

Demand changed

Review PIR, actual consumption, forecast bias, and customer demand before increasing supply.

Supply is firmed or late

Review the open proposal or order, vendor/production commitment, date, quantity, and controlled rescheduling options.

Stock is unusable

Review stock type, quality hold, shelf life, location, allocation, and physical accuracy before calling the shortage a planning failure.

PLANNER MOMENT

MRP proposes more stock while the warehouse is full

Before cancelling production, compare the remaining PIR, actual consumption, stock age and type, firmed supply, and safety-stock rule. The proposal may reflect real future demand—or a forecast that was not consumed as designed.

Keep the original signal visible
Correct the owning data or document
Run the next MRP result as proof

CONTINUEControl inventory risk

Use the resulting stock position to test service, excess, ageing, and obsolescence.

Open inventory control