What is the MPS and MRP in Textiles?

In the textile industry, MPS (Master Production Scheduling) and MRP (Material Requirements Planning) are essential planning systems that ensure smooth production, efficient resource utilization, and timely order fulfillment.

1. Master Production Scheduling (MPS) in Textiles

MPS is a high-level production plan that determines what to produce, in what quantity, and when based on demand forecasts and available resources. Master Production Scheduling (MPS) in the textile industry is a high-level production plan that defines what, how much, and when to produce different textile products based on demand forecasts, inventory levels, and production capacity.

MPS helps textile mills and garment factories optimize resources, reduce lead times, and ensure timely order fulfillment.

Key Functions of MPS in Textiles:

✅ Demand-Based Planning: Aligns production with customer orders and market demand.
✅ Capacity Management: Ensures machines, labor, and resources are utilized optimally.
✅ Order Scheduling: Prioritizes production of different fabrics, garments, or textile products.
✅ Minimizing Lead Time: Reduces delays by streamlining production timelines.
✅ Inventory Control: Balances raw material stock levels to avoid excess or shortage.

Example of MPS in a Textile Mill:

A textile company producing cotton fabric plans its monthly production schedule based on orders from brands like H&M and Zara. The MPS ensures that 100,000 meters of cotton fabric are produced by dividing production across different machines while considering fabric dyeing, weaving, and finishing processes.

2. Material Requirements Planning (MRP) in Textiles

MRP is a system used to calculate the raw materials, trims, and components required for production. It ensures that necessary materials are available at the right time to avoid production delays. Material Requirements Planning (MRP) is a system used in the textile and apparel industry to ensure that the right materials (fabric, trims, yarn, dyes, etc.) are available at the right time for efficient production. It helps in reducing waste, controlling costs, and preventing production delays due to material shortages.

Key Functions of MRP in Textiles:

✅ Raw Material Planning: Determines how much yarn, dye, chemicals, or trims are needed.
✅ Supply Chain Coordination: Helps textile mills and garment factories procure materials in advance.
✅ Waste Reduction: Prevents overstocking and material wastage.
✅ Just-in-Time (JIT) Inventory: Orders materials as per production needs to reduce holding costs.

Steps in Material Requirements Planning for Textiles

1. Demand Analysis

• Identifying the required materials based on the Master Production Schedule (MPS).
• Example: A garment factory producing 10,000 polo shirts needs to determine fabric, buttons, and thread requirements.

2. Bill of Materials (BOM) Creation

• Listing all materials needed for each product.
• Example: One polo shirt requires:
  • 1.5 meters of cotton knit fabric
  • 3 buttons
  • 50 cm of sewing thread

3. Material Calculation

• Multiplying the BOM by the total production quantity.
• Example: If making 10,000 polo shirts, the factory needs:
  • 15,000 meters of cotton knit fabric
  • 30,000 buttons
  • 5,000 meters of sewing thread

4. Inventory Check

• Reviewing current stock levels to determine what needs to be ordered.
• Example: If 5,000 meters of fabric are already in stock, only 10,000 meters need to be ordered.

5. Procurement & Supplier Coordination

• Placing purchase orders with suppliers and scheduling deliveries.
• Example: Ordering fabric from a textile mill in India with a lead time of 15 days.

6. Monitoring & Adjustments

Once Master Production Scheduling (MPS) and Material Requirements Planning (MRP) are implemented, continuous monitoring and adjustments are crucial to keep production on track. This ensures that unexpected issues—like supplier delays, demand fluctuations, or machine breakdowns—don’t disrupt operations.

1. Tracking Material Availability (MRP Monitoring)

✅ Regular Inventory Checks → Ensure raw materials (fabric, trims, threads) are available.
✅ Supplier Performance Monitoring → Track whether suppliers are delivering materials on time.
✅ Alternative Material Sourcing → Find backup suppliers for urgent needs.

🔹 Example: If a shipment of denim fabric is delayed, the factory may need to adjust production schedules or source from another supplier.

2. Production Progress Tracking (MPS Monitoring)

✅ Daily Production Reports → Compare actual production with planned targets.
✅ Machine Utilization Analysis → Identify downtime or bottlenecks.
✅ Operator Efficiency Monitoring → Ensure workers meet expected productivity levels.

🔹 Example: If production of T-shirts falls behind by 5,000 units, extra shifts or overtime might be scheduled to meet deadlines.

3. Demand & Order Adjustments

✅ Customer Order Tracking → Monitor changes in demand.
✅ Forecast Updates → Adjust production based on new market trends.
✅ Emergency Order Management → Prioritize urgent customer orders.

🔹 Example: If a major retailer increases an order from 20,000 to 30,000 polo shirts, MPS must be adjusted, and MRP must ensure enough fabric and trims are available.

4. Quality Control & Rework Handling

✅ Defect Rate Monitoring → Identify production defects and adjust materials if needed.
✅ Rework Management → Plan for reworking defective garments without affecting new production.
✅ Supplier Material Quality Checks → Ensure fabric and trims meet quality standards before use.

🔹 Example: If a batch of buttons is defective, MRP needs to reorder them, and production schedules may shift.

5. Supplier & Logistics Adjustments

✅ Lead Time Monitoring → Track supplier delivery times and adjust procurement schedules.
✅ Shipment Delays Handling → Plan buffer stock for critical materials.
✅ Alternative Transport Planning → Arrange faster shipping if needed.

🔹 Example: If a fabric supplier has a 10-day delay, MRP can adjust by reordering from a local supplier with a shorter lead time.

6. Cost & Waste Reduction Strategies

✅ Material Waste Tracking → Identify areas of high fabric or trim waste.
✅ Lean Manufacturing Adjustments → Reduce unnecessary steps in production.
✅ Energy & Resource Optimization → Monitor power and water usage in textile processing.

🔹 Example: If fabric waste is 8% instead of 5%, adjustments can be made in cutting patterns to minimize losses.

Example of MRP in a Garment Factory

A t-shirt factory planning to produce 50,000 cotton t-shirts creates an MRP system like this:

Benefits of MRP in Textiles

✅ Prevents Material Shortages → Ensures all raw materials are available before production starts.
✅ Optimizes Inventory → Avoids excessive stockpiling, reducing warehouse costs.
✅ Reduces Production Delays → Helps manufacturers meet deadlines by ensuring a smooth flow of materials.
✅ Improves Supplier Coordination → Ensures timely deliveries and better supplier relationships.
✅ Enhances Cost Control → Minimizes wastage and prevents unnecessary raw material purchases.

Challenges in MRP for the Textile Industry

⚠ Unpredictable Lead Times → Supplier delays can affect production schedules.
⚠ Material Quality Issues → Receiving defective fabric or trims can halt production.
⚠ Changing Customer Orders → Last-minute order modifications impact material requirements.
⚠ High Product Variety → Different sizes, colors, and designs complicate planning.

How MRP Works with MPS in Textiles

Master Production Scheduling (MPS) and Material Requirements Planning (MRP) work together to ensure smooth and efficient textile production.

📌 MPS (Master Production Schedule) → Defines WHAT to produce, HOW MUCH, and WHEN based on demand.
📌 MRP (Material Requirements Planning) → Determines WHAT MATERIALS are needed, HOW MUCH, and WHEN to procure them.

By integrating MPS and MRP, textile manufacturers can avoid production delays, reduce inventory costs, and improve efficiency.

Example of MRP in a Textile Factory:

A textile factory receives an order to produce 30,000 cotton polo shirts in 6 weeks. To ensure smooth production, the Material Requirements Planning (MRP) system calculates the exact quantity of raw materials needed and schedules procurement accordingly.

Step-by-Step MRP Implementation

1️⃣ Identifying Raw Material Requirements (Bill of Materials – BOM)

Each polo shirt requires:

• 1.5 meters of cotton fabric
• 3 buttons
• 50 cm of thread
• 1 woven label

🔹 Total raw material needed for 30,000 shirts:

• Fabric: 30,000 × 1.5m = 45,000 meters
• Buttons: 30,000 × 3 = 90,000 buttons
• Thread: 30,000 × 50cm = 15,000 meters
• Labels: 30,000 × 1 = 30,000 labels

2️⃣ Checking Inventory

Before placing new orders, the factory checks existing stock:

3️⃣ Supplier Lead Time & Order Placement

The MRP system schedules orders based on supplier lead times:

4️⃣ Production Scheduling Based on Material Arrival

Final Outcome

✅ MRP ensures that all raw materials arrive before production starts, avoiding delays.
✅ The factory meets the 6-week deadline and delivers 30,000 shirts on time.
✅ Material costs are controlled, preventing excess stock or shortages.

Benefits of MRP in Textile Manufacturing

✔ Reduces waste by ordering the exact material quantity.
✔ Optimizes cash flow by preventing over-purchasing.
✔ Prevents production delays by ensuring timely material availability.
✔ Improves supplier management through scheduled orders.

MRP ensures all these materials arrive on time, preventing production delays.

Difference Between MPS and MRP in Textiles

How MPS & MRP Work Together in Textile Industry

1️⃣ MPS defines production goals → “We need 50,000 shirts this month.”
2️⃣ MRP calculates material needs → “Order 5,000 meters of fabric and 10,000 buttons.”
3️⃣ Both systems synchronize production and material supply for efficiency.