Material Planning

Ensuring availability

PSIpenta Material Planning ensures that all material requirements from sales and production are covered in good time. A wide variety of consumption-driven and demand-driven procedures allow quantities and dates to be accurately calculated. Purchase order proposals and work orders are created on the basis of continuous availability checking.


  • Different requirements planning procedures: gross, net, flexible lot sizes, maximum quantity; order point, stochastic etc.
  • Order reference up to anonymous levels and also across plants
  • Interrelationship of phantom assemblies in the production structure
  • Security requirements and material allocated quantities
  • Generation of work order structure using requirements planning
  • Generation of work order structure by merging individual, finished assemblies one by one until the overall structure is complete, activation of the assemblies with availability check depending on design progress
  • Production and purchasing of one-off items (parts without item numbers)
  • Subcontracting of assemblies and material provisions, multi-stage automatic or manual
  • Purchase order calls and plant purchase orders
  • Preliminary planning of parts with long delivery times
  • A variety of approaches in critical situations and the possibility to test for changed behaviour
  • Handling make-or-buy decisions
  • Direct triggering of delivery calls based on basic contracts and plant orders (extended workbench)



Materialdisposition ERP-System PSIpenta
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Requirements planning

The Material Planning module ensures that all requirements that occur in the company are covered at the correct time and in the correct quantity. Requirements planning is particularly effective when used for planning standard items and for the preproduction and procurement of warehouse inventory parts. Standard planning procedures are used to automatically generate work orders and purchase order proposals from standardised basic data. As well as the planning of single items, simultaneous planning of primary and by-products (co-production) is supported. Customer-based requirements, either with a high degree of variance or of a unique nature, are planned using the versatile options for composing work orders and detail planning.

Requirements planning procedure

Requirements planning can either cover specific requirements, e.g. for customer orders, or be based on the average consumption of an item, regardless of current individual requirements, ensuring that sufficient stock is always on hand.

Requirements-based method

Starting from current requirements, coverage on the requirement date is ensured. For example, this can prevent excessive capital tie-in due to high levels of stock on-hand. For expensive or difficult to store items, it is beneficial to use a more complex method, in which the exact requirements quantity and the exact requirement date are identified for each individual order. Requirement-based planning is possible with an availability check (net calculation) or without an availability check (gross calculation).

Consumption-based method

For items consumed in large volumes, exact calculation of each individual requirement quantity for every customer transaction or work order is not economical. Less complex methods are more suitable for items that are easy to store. Either a fixed minimum stock on-hand (reorder point) is used, below which the stock may not fall, or the expected monthly requirement quantity is derived from the past consumption data. A limited inventory can guarantee continuous availability for delivery and eases the planning process.

Order calculation process

The receipt quantity to be procured must never be the same as the requirement quantity. To minimise procurement costs, more economical batch sizes or order quantities can often be achieved here than would result from simply scheduling the gross requirement quantity or the shortfall quantity. Requirements planning then always plans the item based on these specifications. Using the different strategies for creating batch sizes and merging them together, material planning, capacity planning and the associated organisational work can be optimised considerably.

Safety stock

In PSIpenta ERP, it is possible to create stock on-hand with limited availability as security. Security requirements involve maintaining stock that is available in case of an emergency. In this way, the material planner always reserves a certain stock on-hand for the production planner, which can be issued immediately as a spare part delivery or after-sales service requirement if needed.

Material allocated quantity

Material allocated quantity is used to reserve existing on-hand stock of an item for a particular customer transaction line or a work order. For example, this is useful if the customer transaction may result in material requirements that have to be covered immediately and for which procurement within the normal procurement time is not possible.