High-Efficiency MRP Extensions & Optimization Engineering

Fireant MRP Extensions are engineered to bridge the critical gap between “Standard ERP Logic” and “Real-World Material Complexity.” We don’t replace your existing ERP; we augment it. While most MRP systems handle basic inventory math, they often fail to account for the nuances of modern manufacturing like dynamic lead times, shelf-life sensitivity, and multi-tier supplier volatility.

Our extensions serve as a Precision Layer that sits on top of your current system, transforming generic material calculations into actionable, high-integrity procurement and production triggers.

Core Architecture Objectives

  • Constraint-Aware Requirements
    Move beyond simple "Min/Max" levels. Our extensions factor in batch sizes, supplier reliability, and transport volatility to ensure material arrival is perfectly timed.
  • Dynamic Lead-Time Correction
    Automatically adjust planning parameters based on actual historical performance rather than static "ideal" data found in the Part Master.
  • Automated Exception Management
    Shift from "Screen-Watching" to "Exception-Planning." The system only alerts you when material shortages or surpluses deviate from your safety buffers.
  • Bi-Directional Shop Floor Sync
    Link material consumption directly to the shop floor’s actual pace, ensuring that "Material-on-Hand" reflects reality, not just the last paper transaction.

The User Ecosystem

  • Procurement & Purchasing
    Automated, high-integrity "Buy Lists" that account for lead-time shifts and volume discounts.
  • Inventory Controllers
    Real-time visibility into "Dead Stock" risk and aging inventory alerts.
  • Production Planners
    Confidence that the "Material Clear" status for a work order is backed by real-time data.
  • Warehouse Managers
    Optimized staging and kitting lists aligned with the actual sequence of production.

Why Fireant Extends "Standard" MRP Modules

Most manufacturers find that their “Off-the-Shelf” ERP/MRP modules fall short because of:

  • Rigid Logic (The "Average" Trap)
    Standard MRPs use static averages for lead times and scrap rates. In reality, these variables change weekly.
  • The "Black Box" Problem
    It’s often impossible to see why an MRP suggested a specific purchase, leading to planners manually double-checking every line in Excel.
  • Poor Handling of Variability
    Standard systems struggle with "High-Mix" environments where material requirements fluctuate wildly based on small changes in the production schedule.
  • Lack of Supplier Intelligence
    Generic modules assume every supplier is 100% on time. Fireant Extensions build "Supplier Trust Scores" into the material logic.

Our Engineering Approach

At Fireant, we don’t just build “calculators”; we build Decision Support Intelligence. Our MRP Extension architecture is centered on the harsh reality of global supply chain volatility, where lead times are suggestions and material availability is the primary bottleneck.

Design Principles

  • Algorithmic Agility
    Fireant Extensions use multi-heuristic solvers to go beyond simple subtraction. Whether you prioritize "Minimum Inventory Carrying Cost" or "Maximum Production Buffer," the system recalculates your procurement triggers based on your specific strategic goals.
  • "Digital Twin" Supply Chain
    We model your material flow with granular precision—factoring in vendor-specific transit times, port congestion variables, and internal quality-inspection queues for every Part Number.
  • Live Shop-Floor Feedback Loop
    Integration isn't a luxury; it’s a requirement. Fireant pulls live consumption data from the MES. If the floor is burning through material 10% faster than the ERP expected, the extension adjusts your "Buy Suggestions" instantly to prevent a stockout.
  • Visual Intelligence (VI)
    We prioritize high Information Density. Our interactive VI dashboards use color-coding to highlight critical shortages, "Ghost Inventory," and high-risk POs, allowing buyers to "see" the supply gap before it halts production.

The Fireant Impact:

  • 15% – 25% Reduction in Excess Inventory holding costs within the first 6 months.

  • Zero “Material Fires”: Replace urgent, high-cost air-freight shipments with data-driven early warning alerts.

  • Increased Buyer Productivity: Automate 80% of routine PO suggestions, allowing your team to focus on strategic sourcing and vendor negotiation.

The Transformation: Bridging the MRP Gap

Industry Pain PointThe Fireant Extension SolutionStrategic Business Impact
Static Lead TimesDynamic Lead-Time Engine: Recalculates lead times based on the last 5 actual deliveries.Reduced Stockouts: Aligns procurement with the current reality of the supply chain.
Inventory "Bloat"Safety Stock Optimizer: Uses standard deviation and demand volatility to set lean buffers.Cash Flow Optimization: Releases capital locked in unnecessary "Just-in-Case" stock.
Manual Kitting ErrorsDigital Kitting Interface: Real-time validation of material picking against active Work Orders.Floor Efficiency: Prevents production halts caused by missing small-scale components.
Unreliable ERP DataAutomated Data Scrubbing: Flags "Ghost Inventory" and identifies data entry errors in real-time.Data Integrity: Replaces "Guess-work" with a high-fidelity Material Thread.

The “Fireant Difference” in Practice

Most off-the-shelf systems solve these problems by forcing you to change your company’s culture to fit their software. Fireant does the opposite. We look at your specific manufacturing constraints (whether it’s high-mix/low-volume production or strict regulatory oversight), and configure the MRP modules to automate the exact points where your team currently feels the most “friction.”

System Architecture & Technical Foundation

The Fireant MRP Extension is engineered as a high-integrity data orchestration layer. It is designed to process massive datasets from your ERP and supply chain in real-time, providing a “High-Resolution” view of your material requirements that standard systems miss.

Structural Layering

  • Demand & Supply Logic Engine
    The "Brain" of the extension. It handles complex material dependencies, such as "Part X can be substituted by Part Y only for Project Z," or calculating safety stocks based on Poisson distribution rather than simple averages.
  • Event-Driven Integration Layer
    A high-speed API gateway that listens for "Inventory Adjustments" from the warehouse or "New Sales Orders" from the ERP, triggering immediate recalculations of your "Net Requirements."
  • Predictive Lead-Time Layer
    Uses machine learning to analyze historical vendor performance. It "auto-corrects" the lead times in your Part Master, ensuring your purchase triggers account for real-world supplier delays.
  • Multi-Tenant Cloud/Hybrid Core
    A secure, scalable infrastructure that allows procurement teams to manage material across multiple global sites and warehouses from a single, centralized command center.

The Connected Factory

  • ERP / MRP (SAP, Odoo, Oracle)
    Acts as the primary data source. We pull the "Static" plan and push back "Optimized" purchase and production triggers.
  • MES & Shop Floor
    Direct linkage to actual material consumption rates, ensuring that the "Inventory-on-Hand" in the office matches the "Physical-Stock" on the floor.
  • Supplier Portals
    An optional integration layer that allows your vendors to update their shipping status directly into your MRP logic, providing a live "Arrival-at-Port" visibility.
  • Quality Systems (QMS)
    Real-time linkage to "Rejected" or "Quarantined" stock, ensuring that faulty material is instantly removed from the "Available-to-Promise" calculation.

Industrial-Grade Security

  • Granular RBAC
    Control who can override "Buy Suggestions" or modify safety stock parameters based on seniority and department.
  • AES-256 Encryption
    All proprietary BOM structures and supplier pricing data are encrypted both at rest and in transit.
  • Forensic Audit Trails
    An immutable ledger capturing every manual override of an MRP suggestion, ensuring 100% accountability for inventory "bloat" or "shortages."
  • Multi-Factor Authentication (MFA)
    Mandatory verification for high-value Purchase Order approvals or modifications to the Master Production Schedule (MPS).

The Fireant "Rapid-Deploy" Implementation Framework

We follow a 6-Phase Methodology to move your factory from “Reactive” to “Predictive.”

Phase 1: Industrial Discovery & Constraint Mapping

We don’t just look at your software; we look at your warehouse floor and supplier contracts.

  • The Goal: Reverse-engineer your existing “Manual Buffers,” uncovering where your team currently uses “Hidden Excel Sheets” to manage material gaps.

  • The Output: A Material Maturity Roadmap and a gap analysis of your current ERP’s logic failures.

Phase 2: Agile Logic Configuration

Leveraging the Fireant Extension Engine, we build the mathematical overlays.

  • The Goal: Configure (not customize) the specific logic extensions—such as “Shelf-Life Alerts” or “Component Substitution Rules.”

  • The Output: A functional prototype of the Material Exception Dashboard linked to your live data.

Phase 3: The “Digital Bridge” (ERP Hook-In)

This is where Fireant’s technical DNA enhances your existing investment.

  • The Goal: Establish a deep-link API connection to your ERP (Odoo, SAP, Oracle) to pull inventory levels and push “Optimized Buy Suggestions.”

  • The Output: A seamless UI experience where planners see “Extended MRP” insights directly within their workflow.

Phase 4: Data Cleansing & Parameter Tuning

The “Garbage In, Garbage Out” rule is most lethal in material planning.

  • The Goal: We assist in scrubbing your Part Master data, correcting “Standard Costs,” and updating obsolete Lead-Time fields.

  • The Output: A high-integrity Material Master that the system can actually trust to make decisions.

Phase 5: User Empowerment & Pilot Launch

We focus on High-Touch Training for your Buyers and Material Controllers.

  • The Goal: Run “Parallel Planning” cycles to prove the Fireant suggestions reduce inventory while maintaining service levels.

  • The Output: A confident procurement team that spends time negotiating with suppliers rather than fighting data.

Phase 6: Post-Launch Optimization & Scaling

MRP logic must adapt as your product line grows.

  • The Goal: Continuous performance monitoring of “Planned vs. Actual” material arrivals.

  • The Output: Quarterly Logic Sprints to refine safety stock levels based on seasonal demand shifts or new supplier onboardings.

The Fireant Timeline Advantage

We accelerate your return on investment by focusing on data integrity and API connectivity from day one.

MilestoneManual / Traditional Ext.Fireant MRP Ext.
First Achievable PlanMonth 4+Week 3-4
Live MES SyncMonth 9+Month 2-3
Full ROI Realization12–18 Months4–6 Months

Investment & Scalability Roadmap

Implementation costs are structured based on your current digital maturity and the depth of integration required. At Fireant, we prioritize a “Value-First” approach, ensuring you don’t pay for features that don’t serve your immediate production goals.

Budget Tier Comparison (Estimated in MYR)

Range Starting from RM60K – RM280K depending on scale and complexity.

Key Investment Drivers

  • Logic Complexity
    The depth of custom rules required (e.g., managing sub-assemblies, "By-Products," or strict shelf-life traceability).
  • Integration Density
    The complexity of "talking" to your specific ERP (Odoo, SAP, Oracle) and how much data needs to be bi-directionally synced.
  • Data Legacy
    The volume and cleanliness of your current Inventory/BOM history and the amount of "Data Scrubbing" required.
  • SLA Requirements
    Custom support tiers, from standard business hours to 24/7 mission-critical response for continuous manufacturing.