MRP System Technical & Interface Report
Budget: $5,000 – $10,000 SGD
Manufacturing Resource Planning (MRP) System: Technical Specifications and Interface Design Report
This comprehensive report presents the detailed technical specifications and graphical interface design for Manufacturing Resource Planning (MRP) system, providing a complete blueprint for system development and implementation.
Executive Summary
The proposed MRP system represents a sophisticated, integrated solution designed to manage manufacturing resources across sales, purchasing, inventory, and production processes. Built on PostgreSQL database architecture with Python Django framework, the system supports up to 50 users with 30 concurrent sessions, handling up to 100,000 drawing numbers with real-time processing capabilities. The system emphasizes user-friendly design for non-IT personnel while maintaining robust security and approval workflows.
System Overview and Architecture
Technical Foundation
The MRP system operates on a robust technical foundation designed for scalability and reliability. The system architecture centers on PostgreSQL database management with Python Django framework, ensuring enterprise-grade performance and maintainability. The intranet-based deployment model provides secure access while enabling email integration for purchase order management and supplier communications.
MRP System Architecture and Data Flow Diagram
System Capacity and Performance
The system specifications accommodate significant operational scale with support for 50 total users and 30 concurrent sessions without latency issues. Data storage capacity extends to 100,000 drawing numbers, with each drawing supporting up to 30 line items (MPNs), resulting in a total capacity of 3 million line items across the system.
System Integration and Technical Architecture
Core Module Specifications and Interface Design
User Management and Security Framework
The user management system implements role-based access control with granular permissions across modules and processes. Two super administrators maintain system-wide management capabilities, including user account creation, password management, and access rights configuration. The system supports skill-level costing models with configurable daily, hourly, and minute rates in multiple currencies.
Sales Module Interface and Functionality
The Sales module provides comprehensive quotation management with automated pricing based on historical purchase data. The interface supports Bill of Materials (BOM) management, linking customer child part numbers to internal Manufacturing Part Numbers (MPNs). Cost calculations incorporate material costs, tolerance percentages, SGA, material burden, and freight costs with enforced markup parameters.
Sales Module Interface with BOM Management
Key features include Excel-based import/export capabilities for drawings and work orders, real-time pricing updates, and automated shortage calculations. The system supports alphanumeric drawing numbers and maintains comprehensive audit trails for all pricing decisions and modifications.
Work Order Management System
The Work Order module facilitates comprehensive project management through Excel-based import/export functionality. The system performs duplication checks based on project number, PO number, and position number combinations, ensuring data integrity across all work orders. Real-time inventory checking triggers automated shortage alerts and purchasing actions.
Production release requires supervisor authorization before work orders become available to production teams. The maintenance functionality allows supervisors to purge and reload work order data after confirmation and export procedures.
Inventory Management Interface
The Inventory module provides real-time stock monitoring with comprehensive visibility into balance quantities, incoming stock, and storage locations. The system implements receiving controls with configurable date windows before need dates, preventing premature goods receipt. Automated shortage alerts consolidate requirements across multiple drawings and projects.
Inventory Management Module Interface
The module supports materials needed consolidation with Excel export capabilities and provides comprehensive MPN usage tracking by customer and project. Real-time inventory deduction occurs automatically during production picking processes.
Purchase Module and Supplier Management
The Purchase module automates PO generation with self-generated numbering based on running numbers and years (e.g., P25-0001). The system maintains historical pricing data and supplier information, supporting up to three suppliers per MPN across multiple currencies including SGD, USD, Euro, and RMB.
Purchase Module Interface with PO Management
Approval workflows trigger second-layer authorization when new prices exceed historical values. The system provides comprehensive PO tracking against need dates with automated supplier acknowledgment reminders and delay alerts.
Production Module and Process Control
The Production module implements strict process sequencing for two distinct workflows: Cable Harness Assembly and Box Build Assembly. Cable Harness Assembly follows a five-step sequential process (Picking, Cable Harness, Labelling, Quality Check, Packing), while Box Build Assembly allows parallel processing between Picking and Assembly operations.
Production Process Workflows for Cable Harness and Box Build Assembly
Each process step records user identification and timestamps, with supervisor-only capabilities for process modifications. The system supports real-time shortage handling with inventory quantity adjustments and comprehensive status tracking across all production activities.
System Integration and Data Flow
Database Architecture and Integration
The central PostgreSQL database serves as the integration hub for all system modules, ensuring data consistency and real-time updates across all operations. The database architecture supports complex relationships between child part numbers, MPNs, suppliers, and customers while maintaining referential integrity and performance optimization.
Email Integration and Document Management
The system includes comprehensive email integration for purchase order distribution and supplier acknowledgment tracking. All POs generate in PDF format with automatic folder creation by year (e.g., "PO2025") for traceability purposes. The system maintains audit trails for all email communications and document generations.
User Workflow and Process Design
The system implements comprehensive user workflows that guide operators through complex manufacturing processes while maintaining flexibility for experienced users. The workflow design emphasizes error prevention through validation checks, approval requirements, and supervisor override capabilities.
MRP User Workflow and Process Flow
Real-time status updates ensure all stakeholders maintain current visibility into production progress, material availability, and potential delays. The system provides automated alerts and notifications to appropriate personnel based on predefined criteria and thresholds.
Implementation Recommendations
Technical Implementation Strategy
The system development should follow an iterative approach with module-by-module implementation to ensure thorough testing and user acceptance. Initial deployment should focus on core modules (User Management, Sales, Inventory) before expanding to advanced features (Production, Purchase integration).
Database optimization should prioritize indexing strategies for frequently accessed data, particularly drawing numbers, MPNs, and customer information. Performance monitoring should be implemented from the initial deployment to ensure system scalability meets projected user growth.
User Training and Change Management
The system's emphasis on user-friendly design for non-IT personnel requires comprehensive training programs tailored to different user roles and experience levels. Training should include hands-on practice with real data scenarios and comprehensive documentation for all system functions.
Quality Assurance and Testing
Comprehensive testing protocols should validate all integration points between modules, ensuring data consistency and workflow continuity. Special attention should be given to financial calculations, inventory adjustments, and production process sequencing to prevent operational disruptions.
Conclusion
The proposed MRP system represents a comprehensive solution for manufacturing resource planning with sophisticated interface design and robust technical architecture. The system's modular design, user-centric interface, and comprehensive integration capabilities position it to significantly enhance operational efficiency while maintaining the flexibility required for complex manufacturing environments.
The implementation of this system will provide us with a competitive advantage through improved resource utilization, enhanced customer service capabilities, and comprehensive operational visibility. The system's scalability and integration capabilities ensure long-term value and adaptability to evolving business requirements.
Ownership
All programming source codes and the SQL database developed as part of this project shall be the exclusive property of the client.
Upon completion of the project and full payment, all rights, title, and interest in the programming source codes and SQL database, including all related documentation and intellectual property, shall be transferred to and owned by the client
Option
5 year maintenance for this project against bugs, system updates, database cleanup, etc… exclude any new features/functions add on.
This comprehensive report presents the detailed technical specifications and graphical interface design for Manufacturing Resource Planning (MRP) system, providing a complete blueprint for system development and implementation.
Executive Summary
The proposed MRP system represents a sophisticated, integrated solution designed to manage manufacturing resources across sales, purchasing, inventory, and production processes. Built on PostgreSQL database architecture with Python Django framework, the system supports up to 50 users with 30 concurrent sessions, handling up to 100,000 drawing numbers with real-time processing capabilities. The system emphasizes user-friendly design for non-IT personnel while maintaining robust security and approval workflows.
System Overview and Architecture
Technical Foundation
The MRP system operates on a robust technical foundation designed for scalability and reliability. The system architecture centers on PostgreSQL database management with Python Django framework, ensuring enterprise-grade performance and maintainability. The intranet-based deployment model provides secure access while enabling email integration for purchase order management and supplier communications.
MRP System Architecture and Data Flow Diagram
System Capacity and Performance
The system specifications accommodate significant operational scale with support for 50 total users and 30 concurrent sessions without latency issues. Data storage capacity extends to 100,000 drawing numbers, with each drawing supporting up to 30 line items (MPNs), resulting in a total capacity of 3 million line items across the system.
System Integration and Technical Architecture
Core Module Specifications and Interface Design
User Management and Security Framework
The user management system implements role-based access control with granular permissions across modules and processes. Two super administrators maintain system-wide management capabilities, including user account creation, password management, and access rights configuration. The system supports skill-level costing models with configurable daily, hourly, and minute rates in multiple currencies.
Sales Module Interface and Functionality
The Sales module provides comprehensive quotation management with automated pricing based on historical purchase data. The interface supports Bill of Materials (BOM) management, linking customer child part numbers to internal Manufacturing Part Numbers (MPNs). Cost calculations incorporate material costs, tolerance percentages, SGA, material burden, and freight costs with enforced markup parameters.
Sales Module Interface with BOM Management
Key features include Excel-based import/export capabilities for drawings and work orders, real-time pricing updates, and automated shortage calculations. The system supports alphanumeric drawing numbers and maintains comprehensive audit trails for all pricing decisions and modifications.
Work Order Management System
The Work Order module facilitates comprehensive project management through Excel-based import/export functionality. The system performs duplication checks based on project number, PO number, and position number combinations, ensuring data integrity across all work orders. Real-time inventory checking triggers automated shortage alerts and purchasing actions.
Production release requires supervisor authorization before work orders become available to production teams. The maintenance functionality allows supervisors to purge and reload work order data after confirmation and export procedures.
Inventory Management Interface
The Inventory module provides real-time stock monitoring with comprehensive visibility into balance quantities, incoming stock, and storage locations. The system implements receiving controls with configurable date windows before need dates, preventing premature goods receipt. Automated shortage alerts consolidate requirements across multiple drawings and projects.
Inventory Management Module Interface
The module supports materials needed consolidation with Excel export capabilities and provides comprehensive MPN usage tracking by customer and project. Real-time inventory deduction occurs automatically during production picking processes.
Purchase Module and Supplier Management
The Purchase module automates PO generation with self-generated numbering based on running numbers and years (e.g., P25-0001). The system maintains historical pricing data and supplier information, supporting up to three suppliers per MPN across multiple currencies including SGD, USD, Euro, and RMB.
Purchase Module Interface with PO Management
Approval workflows trigger second-layer authorization when new prices exceed historical values. The system provides comprehensive PO tracking against need dates with automated supplier acknowledgment reminders and delay alerts.
Production Module and Process Control
The Production module implements strict process sequencing for two distinct workflows: Cable Harness Assembly and Box Build Assembly. Cable Harness Assembly follows a five-step sequential process (Picking, Cable Harness, Labelling, Quality Check, Packing), while Box Build Assembly allows parallel processing between Picking and Assembly operations.
Production Process Workflows for Cable Harness and Box Build Assembly
Each process step records user identification and timestamps, with supervisor-only capabilities for process modifications. The system supports real-time shortage handling with inventory quantity adjustments and comprehensive status tracking across all production activities.
System Integration and Data Flow
Database Architecture and Integration
The central PostgreSQL database serves as the integration hub for all system modules, ensuring data consistency and real-time updates across all operations. The database architecture supports complex relationships between child part numbers, MPNs, suppliers, and customers while maintaining referential integrity and performance optimization.
Email Integration and Document Management
The system includes comprehensive email integration for purchase order distribution and supplier acknowledgment tracking. All POs generate in PDF format with automatic folder creation by year (e.g., "PO2025") for traceability purposes. The system maintains audit trails for all email communications and document generations.
User Workflow and Process Design
The system implements comprehensive user workflows that guide operators through complex manufacturing processes while maintaining flexibility for experienced users. The workflow design emphasizes error prevention through validation checks, approval requirements, and supervisor override capabilities.
MRP User Workflow and Process Flow
Real-time status updates ensure all stakeholders maintain current visibility into production progress, material availability, and potential delays. The system provides automated alerts and notifications to appropriate personnel based on predefined criteria and thresholds.
Implementation Recommendations
Technical Implementation Strategy
The system development should follow an iterative approach with module-by-module implementation to ensure thorough testing and user acceptance. Initial deployment should focus on core modules (User Management, Sales, Inventory) before expanding to advanced features (Production, Purchase integration).
Database optimization should prioritize indexing strategies for frequently accessed data, particularly drawing numbers, MPNs, and customer information. Performance monitoring should be implemented from the initial deployment to ensure system scalability meets projected user growth.
User Training and Change Management
The system's emphasis on user-friendly design for non-IT personnel requires comprehensive training programs tailored to different user roles and experience levels. Training should include hands-on practice with real data scenarios and comprehensive documentation for all system functions.
Quality Assurance and Testing
Comprehensive testing protocols should validate all integration points between modules, ensuring data consistency and workflow continuity. Special attention should be given to financial calculations, inventory adjustments, and production process sequencing to prevent operational disruptions.
Conclusion
The proposed MRP system represents a comprehensive solution for manufacturing resource planning with sophisticated interface design and robust technical architecture. The system's modular design, user-centric interface, and comprehensive integration capabilities position it to significantly enhance operational efficiency while maintaining the flexibility required for complex manufacturing environments.
The implementation of this system will provide us with a competitive advantage through improved resource utilization, enhanced customer service capabilities, and comprehensive operational visibility. The system's scalability and integration capabilities ensure long-term value and adaptability to evolving business requirements.
Ownership
All programming source codes and the SQL database developed as part of this project shall be the exclusive property of the client.
Upon completion of the project and full payment, all rights, title, and interest in the programming source codes and SQL database, including all related documentation and intellectual property, shall be transferred to and owned by the client
Option
5 year maintenance for this project against bugs, system updates, database cleanup, etc… exclude any new features/functions add on.