 |
| Illustration by Ai |
Efficient material planning can significantly reduce construction costs without compromising project progress, according to a new study by Trio Pendekar Lonan, Daisy D. G. Pangemanan, Estrellita V. Y. Waney, and Nixon Mantiri from Politeknik Negeri Manado, Indonesia. Published in 2026 in the Jurnal Multidisiplin Madani (MUDIMA), the research demonstrates how the Material Requirements Planning (MRP) method helps optimize ready-mix concrete procurement for the Solo Raya Tourism Polytechnic construction project. By comparing three material ordering strategies, the researchers found that the Lot-for-Lot (LFL) method achieved the lowest operational cost, offering a practical solution for improving efficiency in construction project management.
Construction Projects Face
Growing Material Management Challenges
Construction materials account
for one of the largest portions of project expenditure, alongside labor,
equipment, and construction methods. Because of this, effective material
planning has become increasingly important as the construction industry faces
rising material prices, tighter project schedules, and greater pressure to
improve cost efficiency.
In many construction projects,
poor material planning leads to unnecessary expenses. Ordering excessive
quantities ties up capital in unused inventory, while insufficient supplies can
delay construction activities, disrupt project schedules, and increase overall
project costs. Both situations reduce project efficiency and make it more
difficult for contractors to meet budget and completion targets.
The researchers from Politeknik
Negeri Manado explain that these challenges are common during material
procurement, where inaccurate quantity estimates and inefficient delivery
schedules frequently result in either material shortages or excessive stock.
Better planning is therefore essential to ensure that materials arrive in the
right quantity and at the right time.
Against this backdrop, the study
evaluates how the Material Requirements Planning (MRP) method can
improve inventory control for ready-mix concrete used in the construction of
the Solo Raya Tourism Polytechnic Lecture Hall in Central Java.
Research Evaluates Three
Material Ordering Strategies
The researchers conducted a quantitative
case study focusing on the Solo Raya Tourism Polytechnic construction
project between August and December 2023. The project provided an
opportunity to examine how different material planning approaches influence
procurement efficiency during actual construction activities.
To build the analysis, the
research combined both primary and secondary data. Field observations,
interviews with project personnel, and project documentation were used to
understand actual construction conditions and identify material management
challenges. Meanwhile, project documents—including the Bill of Quantities
(BoQ), Unit Price Analysis (AHSP), S-Curve, shop drawings, project schedules,
and material cost records—supplied the numerical information required for
planning calculations.
Using the Material
Requirements Planning (MRP) framework, the researchers calculated gross
material requirements, net material requirements, order timing, and procurement
quantities. They then compared three widely used lot-sizing techniques:
- Lot-for-Lot (LFL)
- Part Period Balancing (PPB)
- Least Unit Cost (LUC)
Each method was evaluated based
on ordering frequency, inventory costs, ordering costs, and total procurement
costs to identify the most economical strategy for ready-mix concrete
procurement.
Key Findings Show Lot-for-Lot
Delivers the Greatest Cost Efficiency
The analysis found that the Material
Requirements Planning (MRP) method provides a systematic way to determine
how much ready-mix concrete should be ordered and precisely when each order
should be placed. Rather than relying on estimates or conventional purchasing
practices, MRP aligns procurement schedules with the project's actual
construction timeline, helping contractors avoid both material shortages and
unnecessary inventory.
After comparing the three
lot-sizing techniques, the researchers identified clear differences in
operational costs.
The Lot-for-Lot (LFL)
method produced the most economical result because materials were ordered only
in the quantities required for each construction period. This approach
eliminated inventory storage costs while maintaining sufficient material
availability throughout the project. As a result, the total operational cost
reached Rp29,580,000, making it the lowest-cost alternative among all
methods evaluated.
By comparison:
- Lot-for-Lot (LFL): Rp29,580,000
- Part Period Balancing (PPB): Rp38,238,205
- Least Unit Cost (LUC): Rp56,442,800
The findings indicate that
although PPB and LUC are designed to balance ordering and storage costs, both
generated higher total expenses than the simpler Lot-for-Lot strategy under the
conditions of the Solo Raya Tourism Polytechnic project.
The researchers also discovered
that improved material planning reduced unnecessary procurement. Through MRP
analysis, the estimated requirement for Fc'25 ready-mix concrete
decreased from 3,475.50 m³ to 3,375.34 m³, demonstrating that
more accurate planning can minimize excess material purchases without affecting
construction activities.
Why the Findings Matter
The study has practical
implications for contractors, project managers, consultants, and public
agencies responsible for construction projects. Material procurement often
represents one of the largest financial commitments in infrastructure
development, meaning even modest improvements in planning can generate
substantial savings.
By implementing the Material
Requirements Planning (MRP) method, construction organizations can:
- Reduce unnecessary inventory and associated storage
costs.
- Improve cash flow by purchasing materials only when
needed.
- Prevent project delays caused by material shortages.
- Increase scheduling accuracy throughout project
execution.
- Improve overall cost control and operational
efficiency.
The researchers emphasize that
selecting the appropriate lot-sizing technique is just as important as adopting
MRP itself. Because every construction project has different characteristics,
contractors should evaluate ordering costs, storage costs, project schedules,
and material demand before deciding which procurement strategy to implement.
As Trio Pendekar Lonan, Daisy
D. G. Pangemanan, Estrellita V. Y. Waney, and Nixon Mantiri of Politeknik
Negeri Manado conclude, the Material Requirements Planning (MRP)
method enables construction managers to plan ready-mix concrete procurement
more systematically, while the Lot-for-Lot technique provides the most
cost-efficient solution for the project examined in this study.
Author Profile
Trio Pendekar Lonan is a
researcher in construction engineering at Politeknik Negeri Manado,
Indonesia. This study was conducted with Daisy D. G. Pangemanan, Estrellita
V. Y. Waney, and Nixon Mantiri, whose expertise includes
construction management, project planning, civil engineering, and
infrastructure development. Together, the research team focuses on improving
project efficiency through evidence-based planning and engineering management.
Source
Article Title: Control
of Materials and Costs for Ready-Mix Concrete Using the Material Requirements
Planning Method
Journal: Jurnal
Multidisiplin Madani (MUDIMA)
Volume: 6, Issue 6
Publication Year: 2026
Pages: 705–718
DOI: https://doi.org/10.55927/mudima.v6i6.67
0 Komentar