{"id":4754,"date":"2020-03-03T11:14:47","date_gmt":"2020-03-03T11:14:47","guid":{"rendered":"https:\/\/www.mrpeasy.com\/blog\/?p=4754"},"modified":"2025-09-26T13:07:00","modified_gmt":"2025-09-26T13:07:00","slug":"different-purchasing-practices-for-manufacturers","status":"publish","type":"post","link":"https:\/\/www.mrpeasy.com\/blog\/different-purchasing-practices-for-manufacturers\/","title":{"rendered":"Different purchasing practices for manufacturers"},"content":{"rendered":"\n<p><strong>A robust and accurate planning system is critical to any manufacturer. In this article, we are comparing different purchasing practices &#8211; ROP\/ROQ Principles vs MRP System Planning<\/strong>.<\/p>\n\n\n\n<!--more-->\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter\"><img loading=\"lazy\" decoding=\"async\" width=\"1000\" height=\"667\" src=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2020\/03\/different-purchasing-practices-for-manufacturers.jpg\" alt=\"different-purchasing-practices-for-manufacturers\" class=\"wp-image-4760\" srcset=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2020\/03\/different-purchasing-practices-for-manufacturers.jpg 1000w, https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2020\/03\/different-purchasing-practices-for-manufacturers-300x200.jpg 300w, https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2020\/03\/different-purchasing-practices-for-manufacturers-768x512.jpg 768w\" sizes=\"auto, (max-width: 1000px) 100vw, 1000px\" \/><\/figure>\n<\/div>\n\n\n<p>A robust and accurate planning system is critical to any manufacturer.&nbsp; However, unlike larger producers, small and medium-sized businesses (SMB) are often much more cash conscious as a matter of survival and or to shelter their growth plans.&nbsp;If the plan is too aggressive, companies may find themselves with too much inventory, tying up valuable cash-flow required for day to day operations.&nbsp; If the plan is too timid, companies may find themselves with stockouts that cause loss or cancellation of orders.<\/p>\n\n\n\n<p>One long-running discussion on the value of which planning system to use has centered on whether a manufacturer should use a <strong>Reorder Point \/Reorder Quantity planning system (ROP\/ROQ) versus a Materials Requirement System (MRP) software.<\/strong>&nbsp; To understand which is best, it helps to look at what each system really is.<\/p>\n\n\n<div class=\"banner-v2\">\n    <p class=\"banner-v2__desc\">Improve your purchasing practices with MRPeasy<\/p>\n    <a class=\"banner-v2__link\" href=\"https:\/\/www.mrpeasy.com\/sign-up\/\" target=\"_blank\" data-ga-event=\"blog_signup_banner_blue\">Try for free<\/a>\n<\/div>\t\t<style>.banner-v2 {\n    float: right;\n    display: flex;\n    flex-direction: column;\n    justify-content: center;\n    align-items: center;\n    padding: 40px 32px;\n    gap: 16px;\n    width: 356px;\n    height: 205px;\n    background: linear-gradient(199.68deg, #6084E5 13.17%, #5FA7DD 82.1%);\n    border-radius: 4px;\n    margin-left: 12px;\n    margin-bottom: 12px;\n    margin-top: 15px;\n}\n\n@media (max-width: 767.98px) {\n    .banner-v2 {\n         width: 100%;\n         height: 173px;\n         margin-bottom: 0;\n         margin-left: 0;\n    }\n}\n\n.single__content p.banner-v2__desc {\n    margin: 0 !important;\n}\n\np.banner-v2__desc {\n    width: 292px;\n    font-style: normal;\n    font-weight: 700;\n    font-size: 22px;\n    line-height: 29px !important;\n    text-align: center;\n    color: #FFFFFF;\n    margin: 0 !important;\n    order: 0 !important;\n}\n\n.single__content a.banner-v2__link {\n    color: #FFFFFF !important;\n}\n\n.single__content a.banner-v2__link:hover {\n    color: #003557 !important;\n}\n\na.banner-v2__link {\n    display: flex;\n    justify-content: center;\n    align-items: center;\n    width: 181px;\n    height: 51px;\n    padding: 18px 0;\n    border-radius: 4px;\n    background: #003557;\n    font-weight: 700;\n    font-size: 16px;\n    color: #FFFFFF !important;\n    text-decoration: none !important;\n    order: 1 !important;\n}\n\n.banner-v2__link:hover {\n    background: white;\n    color: #003557 !important;\n}<\/style>\n\t\t\n\n\n<div id=\"ez-toc-container\" class=\"ez-toc-v2_0_80 counter-hierarchy ez-toc-counter ez-toc-custom ez-toc-container-direction\">\n<div class=\"ez-toc-title-container\">\n<p class=\"ez-toc-title\" style=\"cursor:inherit\">Table of Contents<\/p>\n<span class=\"ez-toc-title-toggle\"><a href=\"#\" class=\"ez-toc-pull-right ez-toc-btn ez-toc-btn-xs ez-toc-btn-default ez-toc-toggle\" aria-label=\"Toggle Table of Content\"><span class=\"ez-toc-js-icon-con\"><span class=\"\"><span class=\"eztoc-hide\" style=\"display:none;\">Toggle<\/span><span class=\"ez-toc-icon-toggle-span\"><svg style=\"fill: #343333;color:#343333\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" class=\"list-377408\" width=\"20px\" height=\"20px\" viewBox=\"0 0 24 24\" fill=\"none\"><path d=\"M6 6H4v2h2V6zm14 0H8v2h12V6zM4 11h2v2H4v-2zm16 0H8v2h12v-2zM4 16h2v2H4v-2zm16 0H8v2h12v-2z\" fill=\"currentColor\"><\/path><\/svg><svg style=\"fill: #343333;color:#343333\" class=\"arrow-unsorted-368013\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"10px\" height=\"10px\" viewBox=\"0 0 24 24\" version=\"1.2\" baseProfile=\"tiny\"><path d=\"M18.2 9.3l-6.2-6.3-6.2 6.3c-.2.2-.3.4-.3.7s.1.5.3.7c.2.2.4.3.7.3h11c.3 0 .5-.1.7-.3.2-.2.3-.5.3-.7s-.1-.5-.3-.7zM5.8 14.7l6.2 6.3 6.2-6.3c.2-.2.3-.5.3-.7s-.1-.5-.3-.7c-.2-.2-.4-.3-.7-.3h-11c-.3 0-.5.1-.7.3-.2.2-.3.5-.3.7s.1.5.3.7z\"\/><\/svg><\/span><\/span><\/span><\/a><\/span><\/div>\n<nav><ul class='ez-toc-list ez-toc-list-level-1 ' ><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-1\" href=\"https:\/\/www.mrpeasy.com\/blog\/different-purchasing-practices-for-manufacturers\/#ROPROQ_Planning\" >ROP\/ROQ Planning<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-2\" href=\"https:\/\/www.mrpeasy.com\/blog\/different-purchasing-practices-for-manufacturers\/#Material_Requirements_Planning\" >Material Requirements Planning<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-3\" href=\"https:\/\/www.mrpeasy.com\/blog\/different-purchasing-practices-for-manufacturers\/#Comparisons_of_the_Two_Systems\" >Comparisons of the Two Systems<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-4\" href=\"https:\/\/www.mrpeasy.com\/blog\/different-purchasing-practices-for-manufacturers\/#Key_takeaways\" >Key takeaways<\/a><\/li><\/ul><\/nav><\/div>\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"ROPROQ_Planning\"><\/span>ROP\/ROQ Planning<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>ROP\/ROQ planning systems are consumption-based planning tools and formulas used to determine when to reorder material and in what quantities.\u00a0 With reorder point planning, orders for material are triggered by the depletion of stock items as orders are placed.\u00a0 Once a stock level for a component reaches a predetermined minimum, an order is placed for that component.\u00a0 This type of planning also uses a <a href=\"https:\/\/www.mrpeasy.com\/blog\/reorder-quantity\/\" target=\"_blank\" rel=\"noreferrer noopener\">Reorder Quantity<\/a> (ROQ) to determine how much stock to order for replenishment.\u00a0 Each of the two segments of this planning method utilizes a simple formula set.<\/p>\n\n\n\n<p><strong><em>ROP =&nbsp; (Lead Time in Days x Unit Sales per Day) + Safety Stock<\/em><\/strong><\/p>\n\n\n\n<p>This then yields the number of units where new components and raw materials orders should be placed to keep the factory running with no stoppage and without holding excess inventory.<\/p>\n\n\n\n<p><strong><em>ROQ = Square Root of ( 2 X Required Quantity X Cost per Order \/ Carrying Cost per Unit)<\/em><\/strong><\/p>\n\n\n\n<p>This then yields the quantity of the component to order at the reorder point.<\/p>\n\n\n\n<p><em>A helpful book &#8211; <\/em><a rel=\"noreferrer noopener\" aria-label=\"Smart Inventory Solutions: Improving the Management of Engineering Materials (opens in a new tab)\" href=\"https:\/\/books.google.ee\/books?id=0r9wKLyQSoIC&amp;source=gbs_navlinks_s\" target=\"_blank\"><em>Smart Inventory Solutions: Improving the Management of Engineering Materials<\/em><\/a><em> By Phillip Slater.<\/em><\/p>\n\n\n\n<p>While the formulas are simple, the two have important distinctions.&nbsp; ROP defines the when of the planning system, and ROQ defines how much.&nbsp; Also, ROQ is simply an inventory planning component, whereas ROP may be influenced by management due to cash-flow and current business conditions.&nbsp; Effectively, ROP is a more strategic and more stable aspect of the system, ROQ is a tactical aspect and one that may change due to many factors.<\/p>\n\n\n\n<p>ROQ also carries with it the impact of a larger number of external factors such as freight costs, volume discounts and other things that affect inventory cost either positively or negatively.&nbsp; As such, it is an operational component that requires additional scrutiny in order to optimize costs.<\/p>\n\n\n\n<p><strong><em>Example<\/em><\/strong><em>: If a factory requires 5000 units of\na component from an overseas supplier and a standard container holds 4,000\nunits, then a decision must be made to optimize the acquisition of the balance\nof the remaining 1,000 units.&nbsp; Shipping\nby another method increases cost, while deferring may risk stockouts.&nbsp; Or, the decision can be made to order two\ncontainers and \u201cgo long\u201d on the additional component to optimize costs.<\/em><\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Material_Requirements_Planning\"><\/span>Material Requirements Planning<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p>While ROP\/ROQ systems can be done manually or with additional software, <a aria-label=\"MRP systems (opens in a new tab)\" href=\"https:\/\/www.mrpeasy.com\/mrp-system\/\" target=\"_blank\" rel=\"noreferrer noopener\">MRP systems<\/a> are software-based inventory planning systems that help automate the planning and purchase of raw materials and components.&nbsp; It is also a forecast based system that takes sales forecast, production capacity and other forecasted aspects of production and develops a plan for components purchases for the <a href=\"https:\/\/www.mrpeasy.com\/blog\/bill-of-materials\/\" target=\"_blank\" rel=\"noreferrer noopener\">Bill of Materials (BOM)<\/a> of all parts required for final production.&nbsp;<\/p>\n\n\n\n<figure class=\"wp-block-image\"><a href=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2020\/03\/software-based-inventory-planning.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"301\" src=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2020\/03\/software-based-inventory-planning-1024x301.jpg\" alt=\"software-based-inventory-planning\" class=\"wp-image-4757\" srcset=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2020\/03\/software-based-inventory-planning-1024x301.jpg 1024w, https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2020\/03\/software-based-inventory-planning-300x88.jpg 300w, https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2020\/03\/software-based-inventory-planning-768x226.jpg 768w, https:\/\/www.mrpeasy.com\/blog\/wp-content\/uploads\/2020\/03\/software-based-inventory-planning.jpg 1919w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/a><figcaption class=\"wp-element-caption\"> Overview of <a href=\"https:\/\/www.mrpeasy.com\/inventory-management\/\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\"inventory management (opens in a new tab)\">inventory management<\/a>.  The stock section is designed for the stock manager.<\/figcaption><\/figure>\n\n\n\n<p>MRP systems also incorporate data such as quality, labor, process routing, FIFO, <a href=\"https:\/\/www.mrpeasy.com\/blog\/procurement-planning\/\" target=\"_blank\" rel=\"noreferrer noopener\">to create an optimized purchasing plan<\/a> for all components.&nbsp; This helps companies maintain lower inventory levels while ensuring that the levels held are optimized for production resulting in a balance where few materials are held in excess yet stockouts do not occur.&nbsp;<\/p>\n\n\n\n<p>MRP systems generally work backward from a production plan and use the Bills of Material to determine the raw materials required.&nbsp; The system answers not only when and how much, but what is required.&nbsp; This is done by using internal and external forecasting to determine what timeframe is required for ordering and completion.&nbsp; The forecasts and plan can be used over relatively shorter or longer time periods, depending on the total lead time required for production or for planning far ahead.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Comparisons_of_the_Two_Systems\"><\/span>Comparisons of the Two Sy<strong>stems<\/strong><span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<p><a aria-label=\"MRP (opens in a new tab)\" href=\"https:\/\/www.mrpeasy.com\/material-requirements-planning\/\" target=\"_blank\" rel=\"noreferrer noopener\">MRP<\/a> is a forecast-based planning system while ROP\/ROQ is a non-forecasted planning system.&nbsp; Many argue that ROP\/ROQ systems are more dependable because they can allow for reaction to greater levels of uncertainty involved in some production environments.&nbsp; For example, it has been noted that ROP\/ROW planning is useful when raw materials and components are difficult or impossible to forecast.&nbsp; <\/p>\n\n\n\n<p>ROP\/ROQ is also said to be a good choice when demand is extremely stable, with only slight variations over time.&nbsp; This would include commodified high-volume goods where the unit cost is very small.&nbsp; <\/p>\n\n\n\n<p>However, these conceits may be due to legacy issues where the familiar seems a better option, but practice proves otherwise.&nbsp; Academic <a rel=\"noreferrer noopener\" href=\"https:\/\/www.academia.edu\/1870274\/A_Comparison_of_Reorder_Point_and_Material_Requirements_Planning_Inventory_Control_Logic_?auto=download\" target=\"_blank\">studies have shown<\/a> that when tested head to head, MRP systems outperform ROP\/ROQ planning systems on all levels in terms of inventory efficiency.&nbsp; The study further indicated that while issues such as difficult forecasting, hyper-stable demand and fractional cost of the end-use product may significantly reduce the risk of using an ROP system, MRP\u2019s automation and the broader application perform at a much more reliable level by comparison.<\/p>\n\n\n\n<p>MRP planning can also perform reliably across different modes of production including MTO, MTS, ETO or blended modes and still provide benefits through actionable data and reports across a broader spectrum of a manufacturer and its managers.&nbsp; These include planned order schedules, order releases and changes to orders.&nbsp; Managers can use such data to optimize inventory levels, track material flow and requirements, compute optimal lot sizes matched to capacity and labor, and better control calculations for safety stock.<\/p>\n\n\n\n<p>Perhaps the starkest difference is that today\u2019s MRP systems are automated with deep analytical capability built into the platform.&nbsp; ROP\/ROQ planning may utilize a dedicated software or it may not.&nbsp; In the case where it does, this system may be siloed causing interoperability issues with other software and risking the integrity of the data and analysis.&nbsp;And for those that are still done manually, the product and BOM complexity of many finished goods can outrun a human being\u2019s capacity to calculate it and draw useful inferences from those calculations. <\/p>\n\n\n\n<p>Today\u2019s MRP systems are modular, agile, flexible and can often be purchased a la carte.&nbsp; They also tend to be cloud-based, providing up-to-date delivery of advancements and improvements to the software.&nbsp; ROP\/ROQ systems are still a valid planning method.&nbsp; But compared to an MRP system\u2019s ability to provide real-time inventory overview, accurate <a aria-label=\"production planning (opens in a new tab)\" href=\"https:\/\/www.mrpeasy.com\/production-planning\/\" target=\"_blank\" rel=\"noreferrer noopener\">production planning<\/a> and reporting, a broader view of the operation, and the ability to control and manage inventory costs, ROP\/ROQ planning is less dependable, more prone to human error and at the risk introducing error in very complex manufacturing environments. <\/p>\n\n\n<div class=\"banner-v1\">\n    <div class=\"banner__text\">\n        <div class=\"banner-v1__title\">Start reaping the benefits of MRP<\/div>\n        <div class=\"banner-v1__desc\">MRPeasy integrates sales, purchases, inventory, production, and finances to provide your with advanced planning capabilities and an accurate real-time overview of your operations.<\/div>\n        <div><a class=\"banner-v1__link\" href=\"https:\/\/www.mrpeasy.com\/sign-up\/\" target=\"_blank\" data-ga-event=\"blog_signup_banner_white\">Try for free<\/a><\/div>\n    <\/div>\n    <div class=\"banner__img\">\n        <img decoding=\"async\" src=\"https:\/\/www.mrpeasy.com\/blog\/wp-content\/themes\/mrpeasy\/assets\/images\/banner.svg\" alt=\"banner\">\n    <\/div>\n<\/div>\n\n\n\n<h2 class=\"wp-block-heading\"><span class=\"ez-toc-section\" id=\"Key_takeaways\"><\/span>Key takeaways<span class=\"ez-toc-section-end\"><\/span><\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li>A robust and accurate procurement planning system is critical to any manufacturer.<\/li>\n\n\n\n<li>Some of the most important planning systems are Reorder Point \/Reorder Quantity planning system (ROP\/ROQ) and Materials Requirement System (MRP) software.<\/li>\n\n\n\n<li>ROP\/ROQ planning systems are consumption-based planning tools and formulas used to determine when to reorder material and in what quantities.<\/li>\n\n\n\n<li>MRP systems are software-based inventory planning systems that help automate the planning and purchase of raw materials and components.<\/li>\n\n\n\n<li>While ROP\/ROQ still has its uses, modern manufacturers are quickly moving toward implementing MRP systems.<\/li>\n<\/ul>\n","protected":false},"excerpt":{"rendered":"<p>A robust and accurate planning system is critical to any manufacturer. In this article, we are comparing different purchasing practices &#8211; ROP\/ROQ Principles vs MRP System Planning.<\/p>\n","protected":false},"author":4,"featured_media":4760,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[92,94,93,384],"tags":[50,3,4,218,40,17,217,213,219,214],"class_list":["post-4754","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-accounting","category-tips","category-production-planning","category-supply-chain-management","tag-inventory-management","tag-manufacturing","tag-manufacturing-software","tag-material-requirements-planning","tag-mrp","tag-mrp-system","tag-purchasing-practices","tag-rop-planning","tag-rop-roq","tag-roq-planning"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v26.7 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Different purchasing practices for manufacturers - Blog for Manufacturers and Distributors<\/title>\n<meta name=\"description\" content=\"A robust and accurate planning system is critical to any manufacturer. 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