{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,3,19]],"date-time":"2026-03-19T17:00:36Z","timestamp":1773939636272,"version":"3.50.1"},"reference-count":24,"publisher":"MDPI AG","issue":"21","license":[{"start":{"date-parts":[[2025,10,31]],"date-time":"2025-10-31T00:00:00Z","timestamp":1761868800000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"FCT\u2014Funda\u00e7\u00e3o para a Ci\u00eancia e Tecnologia","award":["UID\/00319\/Centro"],"award-info":[{"award-number":["UID\/00319\/Centro"]}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Mathematics"],"abstract":"<jats:p>Demand-Driven Material Requirements Planning (DDMRP) has been proposed as a solution for managing uncertainty and variability in supply chains by combining decoupling, buffer management and demand-driven planning principles. A key element of DDMRP is its inventory replenishment model, which relies on dynamically adjusted inventory buffers rather than fixed stock levels. However, parameterization of these buffers often involves subjective choices, raising concerns about consistency and performance. This paper assesses the DDMRP replenishment model through discrete-event simulation of a multi-echelon, capacity-constrained production system. Two alternative formulations of the safety stock term in the red zone are compared: the original factor-based approach and a revised formula that incorporates measurable variability coefficients. While both safety stock formulations yield similar numerical results, the revised formula enhances transparency and reduces subjectivity. Assessing the impact of introducing a buffer for components in addition to a finished goods buffer further shows that the components buffer can reduce finished goods inventory requirements while maintaining service levels. These findings contribute to a better understanding of the DDMRP replenishment model, offering practical insights for parameter selection and supply chain design.<\/jats:p>","DOI":"10.3390\/math13213483","type":"journal-article","created":{"date-parts":[[2025,11,3]],"date-time":"2025-11-03T14:00:33Z","timestamp":1762178433000},"page":"3483","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":2,"title":["The DDMRP Replenishment Model: An Assessment by Simulation"],"prefix":"10.3390","volume":"13","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-4682-1790","authenticated-orcid":false,"given":"Nuno O.","family":"Fernandes","sequence":"first","affiliation":[{"name":"Instituto Polit\u00e9cnico de Castelo Branco, 6000-767 Castelo Branco, Portugal"},{"name":"ALGORITMI Research Centre, University of Minho, 4710-057 Braga, Portugal"}]},{"given":"Suleimane","family":"Djabi","sequence":"additional","affiliation":[{"name":"Instituto Polit\u00e9cnico de Castelo Branco, 6000-767 Castelo Branco, Portugal"}]},{"given":"Matthias","family":"Th\u00fcrer","sequence":"additional","affiliation":[{"name":"Chair of Factory Planning and Intralogistics, Chemnitz University of Technology, 09111 Chemnitz, Germany"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-8420-0875","authenticated-orcid":false,"given":"Paulo","family":"\u00c1vila","sequence":"additional","affiliation":[{"name":"ISEP, Polytechnic of Porto, rua Dr. Ant\u00f3nio Ber-nardino de Almeida, 4249-015 Porto, Portugal"},{"name":"INESC TEC\u2014Instituto de Engenharia de Sistemas e Computadores, 4200-465 Porto, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-4225-6525","authenticated-orcid":false,"given":"Lu\u00eds Pinto","family":"Ferreira","sequence":"additional","affiliation":[{"name":"ISEP, Polytechnic of Porto, rua Dr. Ant\u00f3nio Ber-nardino de Almeida, 4249-015 Porto, Portugal"},{"name":"Associate Laboratory for Energy, Transports and Aerospace (LAETA-INEGI), 4200-465 Porto, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-5645-3127","authenticated-orcid":false,"given":"S\u00edlvio","family":"Carmo-Silva","sequence":"additional","affiliation":[{"name":"ALGORITMI Research Centre, University of Minho, 4710-057 Braga, Portugal"}]}],"member":"1968","published-online":{"date-parts":[[2025,10,31]]},"reference":[{"key":"ref_1","unstructured":"Ptak, C., and Smith, C. (2011). Orlicky\u2019s Material Requirements Planning 3\/E, McGraw Hill Professional."},{"key":"ref_2","unstructured":"Ptak, C., and Smith, C. (2016). Demand Driven Material Requirements Planning (DDMRP), Industrial Press."},{"key":"ref_3","first-page":"1036","article-title":"Production planning and control in multi-stage assembly systems: An assessment of Kanban, MRP, OPT (DBR) and DDMRP by simulation","volume":"60","author":"Fernandes","year":"2020","journal-title":"Int. J. Prod. Res."},{"key":"ref_4","doi-asserted-by":"crossref","first-page":"166","DOI":"10.1080\/00207543.2018.1464230","article-title":"Demand driven MRP: Assessment of a new approach to materials management","volume":"57","author":"Miclo","year":"2019","journal-title":"Int. J. Prod. Res."},{"key":"ref_5","first-page":"632","article-title":"Material management without forecasting: From MRP to demand driven MRP","volume":"11","author":"Kortabarria","year":"2018","journal-title":"J. Ind. Eng. Manag."},{"key":"ref_6","doi-asserted-by":"crossref","unstructured":"Shofa, M.J., Moeis, A.O., and Restiana, N. (2018). Effective production planning for purchased part under long lead time and uncertain demand: MRP vs demand-driven MRP. Conference Series: Materials Science and Engineering, IOP Publishing.","DOI":"10.1088\/1757-899X\/337\/1\/012055"},{"key":"ref_7","doi-asserted-by":"crossref","first-page":"403","DOI":"10.1016\/j.cirp.2012.03.054","article-title":"Simulation based comparison of safety-stock calculation methods","volume":"61","author":"Schmidt","year":"2012","journal-title":"CIRP Ann."},{"key":"ref_8","doi-asserted-by":"crossref","first-page":"663","DOI":"10.1108\/IJLM-12-2017-0329","article-title":"An inherent differentiation and system level assessment approach to inventory management: A safety stock method comparison","volume":"30","author":"Jonsson","year":"2019","journal-title":"Int. J. Logist. Manag."},{"key":"ref_9","first-page":"100164","article-title":"Operations research models and methods for safety stock determination: A review","volume":"7","author":"Carvalho","year":"2020","journal-title":"Oper. Res. Perspect."},{"key":"ref_10","doi-asserted-by":"crossref","first-page":"6496309","DOI":"10.1155\/2019\/6496309","article-title":"A Mathematical Safety Stock Model for DDMRP Inventory Replenishment","volume":"2019","author":"Lee","year":"2019","journal-title":"Math. Probl. Eng."},{"key":"ref_11","unstructured":"Gershwin, S.B. (1994). Manufacturing Systems Engineering, PTR Prentice Hall Inc."},{"key":"ref_12","doi-asserted-by":"crossref","first-page":"105055","DOI":"10.1016\/j.cor.2020.105055","article-title":"An extension of the reorder point method by using advance demand spike information","volume":"124","author":"Jodlbauer","year":"2020","journal-title":"Comput. Oper. Res."},{"key":"ref_13","doi-asserted-by":"crossref","first-page":"1244","DOI":"10.1057\/palgrave.jors.2602655","article-title":"Determining the reorder point and order-up-to-level in a periodic review system so as to achieve a desired fill rate and a desired average time","volume":"60","author":"Silver","year":"2009","journal-title":"J. Oper. Res. Soc."},{"key":"ref_14","doi-asserted-by":"crossref","first-page":"2461","DOI":"10.1080\/00207540701666824","article-title":"Dynamic re-order point inventory control with lead-time uncertainty: Analysis and empirical investigation","volume":"47","author":"Babai","year":"2009","journal-title":"Int. J. Prod. Res."},{"key":"ref_15","doi-asserted-by":"crossref","first-page":"250","DOI":"10.2307\/1906813","article-title":"Optimal inventory policy","volume":"19","author":"Arrow","year":"1951","journal-title":"Econometrica"},{"key":"ref_16","first-page":"79","article-title":"Using the min\/max method for replenishment of picking locations","volume":"18","author":"Apsalons","year":"2017","journal-title":"Transp. Telecommun. J."},{"key":"ref_17","doi-asserted-by":"crossref","first-page":"436","DOI":"10.1287\/mnsc.46.3.436.12069","article-title":"Quantifying the bullwhip effect in a simple supply chain: The impact of forecasting, lead times, and information","volume":"46","author":"Chen","year":"2000","journal-title":"Manag. Sci."},{"key":"ref_18","doi-asserted-by":"crossref","unstructured":"Habbadi, S., El Mouayni, I., Herrou, B., and Sekkat, S. (2025). New Hybrid Method for Buffer Positioning and Production Control Using DDMRP Logic in Smart Manufacturing. J. Manuf. Mater. Process., 9.","DOI":"10.3390\/jmmp9070219"},{"key":"ref_19","doi-asserted-by":"crossref","first-page":"1054","DOI":"10.1016\/j.ifacol.2024.09.134","article-title":"Demand Driven Material Requirement Planning: Core concepts and analysis of its behavior on a case study","volume":"58","author":"Bayard","year":"2024","journal-title":"IFAC-PapersOnLine"},{"key":"ref_20","first-page":"445","article-title":"Analysis of a Dynamic Capacity Management Approach in DDMRP: Application on A Real Industrial Case","volume":"17","author":"Dessevre","year":"2024","journal-title":"J. Ind. Eng. Manag."},{"key":"ref_21","doi-asserted-by":"crossref","first-page":"8","DOI":"10.1007\/s10287-023-00443-5","article-title":"A theoretical validation of the DDMRP reorder policy","volume":"20","author":"Favaretto","year":"2023","journal-title":"Comput. Manag. Sci."},{"key":"ref_22","doi-asserted-by":"crossref","unstructured":"Maggiar, A., Song, I., and Muharremoglu, A. (2022). Multi-Echelon Inventory Management for a Non-Stationary Capacitated Distribution Network. SSRN Electron. J.","DOI":"10.2139\/ssrn.4154780"},{"key":"ref_23","unstructured":"Law, A. (2024). Simulation Modeling and Analysis, McGraw Hill LLC. [6th ed.]."},{"key":"ref_24","doi-asserted-by":"crossref","first-page":"2179","DOI":"10.1080\/00207540600609297","article-title":"Service-level performance of MRP, kanban, CONWIP and DBR due to parameter stability and environmental robustness","volume":"46","author":"Jodlbauer","year":"2008","journal-title":"Int. J. Prod. Res."}],"container-title":["Mathematics"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/2227-7390\/13\/21\/3483\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2025,11,5]],"date-time":"2025-11-05T08:39:55Z","timestamp":1762331995000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/2227-7390\/13\/21\/3483"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2025,10,31]]},"references-count":24,"journal-issue":{"issue":"21","published-online":{"date-parts":[[2025,11]]}},"alternative-id":["math13213483"],"URL":"https:\/\/doi.org\/10.3390\/math13213483","relation":{},"ISSN":["2227-7390"],"issn-type":[{"value":"2227-7390","type":"electronic"}],"subject":[],"published":{"date-parts":[[2025,10,31]]}}}