SYSPRO MRP Checklist: Setup and Run Review

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9 critical items still open - these are the highest-risk gaps.

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Item master data

Every planned stock code has the correct part category (made, bought or phantom)CRITICALLead times are populated and realistic for purchased and manufactured itemsCRITICALPlanning policy and order quantity rules are set per item or classSafety stock values are reviewed and not left from the original implementationObsolete and inactive stock codes are flagged so they stop generating demandUnits of measure and stocking versus alternative units are consistentCRITICAL

Bills of material and routings

Active BOM structures are free of loops and unintended phantom levelsCRITICALQuantity per and scrap percentages reflect current practiceEffective in and out dates are valid for released revisionsRoutings exist for manufactured items so operation offsets can plan datesComponent supply is set correctly for subcontract and free issue items

Warehouses and supply

Warehouses included in planning are the ones that hold usable stockCRITICALQuarantine, scrap and consignment warehouses are excluded from available stockOpen purchase order due dates are current, not left in the pastCRITICALOpen job due dates and quantities reflect the floorDefault supplier and purchasing lead time are present for bought items

Demand and forecast

Sales order lines carry realistic ship datesCRITICALForecast entries do not double count against confirmed ordersDemand time fences are agreed and documentedInterbranch or inter-company demand is treated as intended

Running and reviewing MRP

Run parameters (regenerative or net change, horizon) are agreed and recordedCRITICALThe run finishes without error messages and the log is reviewedException and action messages are triaged by a named plannerCRITICALSuggested orders are compared with a sample of items by handFirm planned orders are used deliberately and reviewed regularlyA schedule exists for run frequency, such as nightly or weekly

Tick each item you have verified. Critical items cause wrong or missing suggestions when they are wrong, so clear those first.

MRP data health review

Optional: send us your checklist result and we will suggest the quickest data fixes for your planners.

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How to use the checklist

Work through the groups in order: item data, bills and routings, warehouses and supply, demand, and the run itself. Tick items you have verified in your own company and note exceptions. Do the critical items first, since errors there change the plan the most. Run the checklist before go-live, after a major data load, and whenever planners start to distrust the output.

Why these checks matter

Material requirements planning nets demand against stock, scheduled receipts and lead times, then explodes through the bill of materials. Each input is a possible failure. A missing lead time collapses a purchase into the wrong week. An old open purchase order keeps supply that never arrives. A warehouse that should not count can hide a shortage. Treating these as a routine data health check is cheaper than correcting expedites later.

Reading your result

If most critical items are ticked and your planners still see odd results, sample five items and trace the calculation manually from demand to suggestion. If you cannot reproduce the suggestion, a parameter or policy is overriding what you expect. If most critical items are open, fix data first and rerun before changing any planning settings.

Common mistakes

Teams often tune safety stock to hide a lead time problem, or switch to net change runs to save time and then wonder why old demand lingers. Another habit is leaving past due purchase orders open for months. Plan a periodic regenerative run and a clean-up of stale documents to keep the plan honest.

Frequently Asked Questions

Why does SYSPRO MRP suggest nothing for an item?

Common causes are the item not being flagged for planning, no demand within the horizon, enough stock or supply to cover demand, or a warehouse excluded from planning. Check the item's planning settings first, then compare demand and supply by date.

How often should MRP run?

It depends on how fast your demand changes. Many manufacturers run nightly so planners start the day with fresh suggestions, with a full regeneration less often. Pick a cadence, document it, and make sure the people acting on the output know when it last ran.

Should I trust firm planned orders?

Use them deliberately. They hold a decision in place, but they can also hide changes in demand. Review them regularly and release or cancel them so they do not drift away from reality.

Does this apply to other ERPs?

Most of the data checks apply to any MRP engine, including Sage Evolution and Odoo. Screen names and parameters differ, but lead times, bills, supply dates and demand quality drive every system.

If planners spend more time questioning MRP output than acting on it, Netray can build read-only checks over your SYSPRO data that flag missing lead times and stale supply automatically.

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SYSPRO MRP Checklist: Data and Run Review Before You Trust the Plan