Implementation of the MRP System for Production Optimization: A Case Study in a Manufacturing Company in the Food Sector

Abstract

Production optimization in medium-sized bakeries faces challenges such as seasonal variability, perishability of inputs, and reactive planning, which require integrated tools to align demand with production capacity. In the case of Ottone Bakery, located in Chimbote, Peru, the lack of a formal production planning and inventory control system has generated significant mismatches between production and demand, leading to additional costs and an inadequate response to market fluctuations. This study proposes the implementation of the Material Requirements Planning (MRP) system as a solution to improve production efficiency and optimize inventory management. The methodology is based on a quantitative analysis of historical sales and production data to develop demand forecasts, followed by the integration of these forecasts into a Master Production Schedule (MPS). The results show that the implementation of MRP can reduce operating costs by minimizing excess inventory and improving the alignment of production with demand. This work highlights the relevance of adopting advanced planning tools to enhance the competitiveness and sustainability of small and medium-sized enterprises in the food sector.