MRP Excel

http://www.production-scheduling.
com
EXCEL-BASED MRP
TABLE OF CONTENTS
INTRODUCTION
TABLE OF LINKS
THE BUSINESS
DATA FILES:
Item Master
Supplier Master
Bill of Materials (BOM)
Purchase Orders
FINITE SCHEDULE
Make-to-Inventory Logic Explained
MRP CALCULATIONS:
Production Runs
BOM x 3
Allocate Inventory
Purchase Action Report
INVENTORY RATIONING:
Inventory Rationing Logic
Inventory Rationing Calculations
Components Pivot
Products Pivot
http://www.production-scheduling.com
Thank you for downloading this copy of Excel-Based MRP, I hope it will be of use to you.
Why Excel-Based MRP?
Production-Scheduling.com assists manufacturers to develop their own finite scheduling systems in Excel, and
will also custom develop scheduling systems for them. Most of these systems are interfaced to a host MRP/ERP
system, which acts as a repository for demand and inventory data, and will perform Material Requirements
Planning (MRP1) calculations.
However, many clients have approached us to develop MRP within Excel, because either:
- they do not have an MRP system, or
- having generated scheduled dates within Excel, they are unable to upload them to their MRP system, or
- their MRP systems are just too cumbersome and unresponsive
Contact Us
This is a simple example of an MRP system, with a small amount of sample data, but it will also cater for many
thousands of records.
If you need assistance to adapt the system to your own manufacturing process, please do not hesitate to contact
me, Tony Rice at:
Production-Scheduling@Mweb.co.za
Or visit our web site:
www.Production-Scheduling.com
Features
The Excel-Based MRP system has the following features:
- VBA free, no macros, it is all formulas and PivotTables, and nothing is hidden
- demand is generated by a make-to-inventory Finite Schedule, but may also be from another source
- a single level Bill of Material structure
- inventory of raw material and components is allocated to the earliest scheduled product first, and will be
dynamically re-allocated as the schedule changes
- a Purchase Action Report identifies purchase orders which must be placed or chased to meet the schedule
Inventory Rationing
The last 3 sheets of the system addresses a question that many manufacturers have:
"What products should I make with the inventory I have on hand right now?"
The system takes into account raw materials that are used by more than one product, and rations the inventory
across the products so as to even out the product inventory cover as much as possible.
Table of Links
Formula link:
PivotTable link:
Products Pivot
Allocate Inventory
BOM x 3
Production Runs
Finite Schedule
Purchase Orders
Bill of Material
Components Pivot
The Business
Item Master
Supplier Master
Bill of Material
Purchase Orders
Finite Schedule
Production Runs
BOM x 3
Allocate Inventory
Components Pivot
Products Pivot
Supplier Master
Worksheet
Item Master
The Business
Links to :
This shows the worksheets that have links to other woksheets, either by having formulae
that refer to other worksheets, or by having a PivotTable based on a data base in another
worksheet.
F
F
F
F
F
P
F
F
F
P
P
F
P
P
F
P
Chained PivotTables
Data flows from the Finite Schedule to the Purchase Action Report through a chain of links that includes
3 PivotTables:
Finite
Schedule
Production
Runs
P
BOM x 3
Purchase
Orders
Allocate
Inventory
Purchase
Action
Report
Unlike formulas, PivotTables do not change automatically when the data is changed, they need to be refreshed.
You can refresh each PivotTable in turn by right clicking in it, and clicking on Refresh Data.
Alternatively you can click on the Refresh All icon
which will refresh all the PivotTables in the workbook.
You will need to click it 3 times.
Put the Refresh All icon on you toolbar by right clicking on the toolbar, then Cutomise|Commands|Data
find the icon and drag it up onto your toolbar
to be refreshed.
n the workbook.
Outline of the Business
This example is based in a fictional business that makes and sells shampoo.
Product Range
We are a new business, and the product range is small. We have 2 types of shampoo,
Apple Blossom and Fragrant Lemon, and each comes in 3 sizes 100ml, 250ml and 500ml.
Our product range is:
Code
AB100
AB250
AB500
FL100
FL250
FL500
Description
Apple Blossom 100ml
Apple Blossom 250ml
Apple Blossom 500ml
Fragrant Lemon 100ml
Bottles per Carton

48
48
24
48
48
24
Forecast Cartons per Week

1000
1400
800
200
1200
1600
The Process
We buy a base shampoo in bulk, pump it into a blending vessel, add either apple or lemon
essence to it, stir it, pump it into a holding vessel from where it is fed to the filling line where
the bottles are filled, labelled, shrink wrapped 6 together, packed into corrugated cartons,
and stacked on pallets.
Bill of Materials
There is one base shampoo, two fragrances, three bottle sizes and six labels. The 100ml
and 250ml bottles are fitted with a flip top cap, and the 500ml bottle has a screw cap. The
100ml bottles are packed 48 to a small carton, the 250ml is packed 48 in a large carton and
the 500ml uses the same carton but 24 to a carton. Two of the bottle labels are pasted on
the carton, one on each end.
Glue, shrink wrap and adhesive tape for the cartons are considered to be consumables, and
the pallets are hired from a national pallet pool. The minimum that a customer can buy is
one carton, so that is the SKU (stock keeping unit).
Capacities
Blending is quicker than filling, 100ml and 250ml bottles can be filled at 70 per minute, and
500ml bottles at 40 per minute. To change the line from one bottle size to another takes
time, but we shall ignore change over times in this example.
Item Master
The item master file contains details of both finished products and raw materials.
This data would typically be stored in a host system, and transferred to Excel via an ODBC link and MS Query.
Code
AB100
AB250
AB500
FL100
FL250
FL500
BS01
ESA
ESL
BT100
BT250
BT500
CAPF
CAPS
LAB10
LAB25
LAB50
LFL10
LFL25
LFL50
CARS
CARL
Description
Apple Blossom 100ml
Apple Blossom 250ml
Apple Blossom 500ml
Base Shampoo
Apple essence
Lemon essence
Bottle 100ml
Bottle 250ml
Bottle 500ml
Flip cap
Screw cap
Label Apple Blossom 100ml
Label Fragrant Lemon 100ml
Carton small
Carton large
Unit of
Measure
carton
carton
carton
carton
carton
carton
litre
litre
litre
each
each
each
each
each
each
each
each
each
each
each
each
each
Warehouse
FP
FP
FP
FP
FP
FP
RM
RM
RM
RM
RM
RM
RM
RM
RM
RM
RM
RM
RM
RM
RM
RM
Supplier
01
01
01
01
01
01
AC01
CE01
CE01
BP01
BP01
BP01
BP01
BP01
DP01
DP01
DP01
DP01
DP01
DP01
EC01
EC01
Supplier Name
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
Ace Chemicals
Chang Essences
Chang Essences
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Eduardo Corrugates
Eduardo Corrugates
C link and MS Query.

Lead
Time
Days
14
30
30
21
21
21
21
21
7
7
7
7
7
7
21
21
Inventory
1,854
1,470
470
488
1,148
766
34,276
1,494
1,002
122,472
184,968
36,516
65,738
37,818
211,796
266,776
24,964
32,140
83,496
117,354
998
4,368
Supplier Master
Code
AC01
BP01
CE01
DP01
EC01
Supplier Name
Ace Chemicals
Best Plastics
Chang Essences
Dave's Printing
Eduardo Corrugates
Bill of Material
This is a typical structure of a single level bill of materials, describing the relationship between
products and components
Product
AB100
AB100
AB100
AB100
AB100
AB100
AB250
AB250
AB250
AB250
AB250
AB250
AB500
AB500
AB500
AB500
AB500
AB500
FL100
FL100
FL100
FL100
FL100
FL100
FL250
FL250
FL250
FL250
FL250
FL250
FL500
FL500
FL500
FL500
FL500
FL500
Component
BS01
BT100
CAPF
CARS
ESA
LAB10
BS01
BT250
CAPF
CARL
ESA
LAB25
BS01
BT500
CAPS
CARL
ESA
LAB50
BS01
BT100
CAPF
CARS
ESL
LFL10
BS01
BT250
CAPF
CARL
ESL
LFL25
BS01
BT500
CAPS
CARL
ESL
LFL50
Qty
Component Description
4.800 Base Shampoo
48.000 Bottle 100ml
48.000 Flip cap
1.000 Carton small
0.048 Apple essence
50.000 Label Apple Blossom 100ml
12.000 Base Shampoo
48.000 Bottle 250ml
48.000 Flip cap
1.000 Carton large
0.120 Apple essence
12.000 Base Shampoo
24.000 Bottle 500ml
24.000 Screw cap
1.000 Carton large
0.120 Apple essence
4.800 Base Shampoo
48.000 Bottle 100ml
48.000 Flip cap
1.000 Carton small
0.048 Lemon essence
50.000 Label Fragrant Lemon 100ml
12.000 Base Shampoo
48.000 Bottle 250ml
48.000 Flip cap
1.000 Carton large
0.120 Lemon essence
12.000 Base Shampoo
24.000 Bottle 500ml
24.000 Screw cap
1.000 Carton large
0.120 Lemon essence
Purchase Orders
This table lists the components that are on order from the suppliers, and the date they are due to
be delivered.
Code
BS01
BS01
BT100
BT250
BT250
BT250
BT500
BT500
BT500
CAPF
CAPF
CAPS
CAPS
CARL
CARL
CARS
CARS
ESA
ESA
ESL
LAB10
LAB25
LAB25
LAB50
LAB50
LAB50
LFL10
LFL10
LFL25
LFL25
LFL50
LFL50
Description
Base Shampoo
Base Shampoo
Bottle 100ml
Bottle 250ml
Bottle 250ml
Bottle 250ml
Bottle 500ml
Bottle 500ml
Bottle 500ml
Flip cap
Flip cap
Screw cap
Screw cap
Carton large
Carton large
Carton small
Carton small
Apple essence
Apple essence
Lemon essence
Supplier
AC01
AC01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
EC01
EC01
EC01
EC01
CE01
CE01
CE01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
Supplier Name
Ace Chemicals
Ace Chemicals
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Eduardo Corrugates
Eduardo Corrugates
Eduardo Corrugates
Eduardo Corrugates
Chang Essences
Chang Essences
Chang Essences
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Qty
100,000
100,000
40,000
90,000
40,000
50,000
100,000
50,000
50,000
200,000
300,000
100,000
100,000
8,000
5,000
1,000
1,000
60
100
350
50,000
70,000
60,000
20,000
20,000
20,000
10,000
10,000
60,000
60,000
40,000
40,000
Due in
18-Mar-00
30-Mar-00
14-Apr-00
18-Mar-00
1-Apr-00
22-Apr-00
16-Mar-00
1-Apr-00
15-Apr-00
16-Mar-00
7-Apr-00
17-Mar-00
2-Apr-00
14-Mar-00
4-Apr-00
18-Mar-00
26-Apr-00
23-Mar-00
6-Apr-00
3-Apr-00
7-Apr-00
14-Mar-00
21-Mar-00
2-Apr-00
16-Apr-00
30-Apr-00
14-Apr-00
28-Apr-00
17-Mar-00
31-Mar-00
30-Mar-00
13-Apr-00
Make-to-Stock (Inventory) Schedule
This schedule is contained in the MRP system, purely to generate a demand for materials.
Explanations of the fomulae, and how the system is constructed, is contained in Section 42 of the scheduling tutorial, downloadable from
www.production-scheduling.com
Start of the first job:
Product running now:
Quantity committed:
Utilization:
14/3 8:00
AB500
110
35.48%
Product Force
AB500
FL500
Idle
AB500
Idle
FL250
AB250
Idle
AB100
Idle
FL500
Idle
AB500
Idle
FL100
Idle
FL250
Idle
AB250
Idle
AB100
Idle
FL500
Idle
Qty
110
2,580
0
1,234
0
1,960
2,383
0
1,609
0
2,538
0
1,234
0
304
0
1,960
0
2,321
0
1,609
0
2,538
0
AB100
Speed - cartons per hour

Forecast sales - cartons per week
Min cover - weeks
Max cover - weeks
Min cover - cartons
Max cover - cartons
Idle
Run
Force hours Force hours
Opening stock:
0.0
0.6
0.0
14.7
22.4
0.0
0.0
7.1
31.9
0.0
0.0
22.4
0.0
27.2
101.1
0.0
0.0
18.4
21.5
0.0
0.0
14.5
15.1
0.0
0.0
7.1
21.9
0.0
0.0
3.5
21.7
0.0
0.0
22.4
4.8
0.0
0.0
26.5
92.9
0.0
0.0
18.4
17.6
0.0
0.0
14.5
7.8
0.0
Start
14/3 8:00
14/3 8:37
14/3 23:22
15/3 21:48
16/3 4:51
17/3 12:43
18/3 11:07
19/3 14:21
23/3 19:28
24/3 13:51
25/3 11:19
26/3 1:49
26/3 16:56
26/3 23:59
27/3 21:55
28/3 1:23
28/3 23:07
29/3 21:31
30/3 2:21
31/3 4:53
4/4 1:47
4/4 20:10
5/4 13:49
6/4 4:19
Stop
14/3 8:00
14/3 8:37
14/3 23:22
15/3 21:48
16/3 4:51
17/3 12:43
18/3 11:07
19/3 14:21
23/3 19:28
24/3 13:51
25/3 11:19
26/3 1:49
26/3 16:56
26/3 23:59
27/3 21:55
28/3 1:23
28/3 23:07
29/3 21:31
30/3 2:21
31/3 4:53
4/4 1:47
4/4 20:10
5/4 13:49
6/4 4:19
6/4 12:04
AB250
AB500
FL100
175
800
0.5
2.0
400
1,600
88
200
0.5
2.0
100
400
FL250
88
1,000
0.5
2.0
500
2,000
88
1,400
0.5
2.0
700
2,800
88
1,200
0.5
2.0
600
2,400
1,854
1,850
1,763
1,629
1,587
1,397
1,264
1,102
500
2,000
1,872
1,785
1,696
1,654
1,523
1,502
1,373
1,240
1,211
1,053
500
2,000
1,894
1,808
1,762
Projected Inventory - units

1,470
470
488
1,148
1,465
577
487
1,144
1,342
507
470
1,038
1,155
400
443
878
1,096
1,600
435
828
831
1,449
397
600
644
1,342
370
2,400
2,800
1,212
338
2,205
1,957
731
217
1,483
1,804
643
195
1,352
1,625
541
170
1,198
1,504
472
152
1,095
1,379
400
135
987
1,320
1,600
126
937
1,137
1,496
100
780
1,108
1,479
400
755
927
1,376
374
600
740
1,269
347
2,400
700
1,246
342
2,365
2,800
1,120
310
2,176
2,026
678
199
1,512
1,873
590
178
1,381
1,725
506
156
1,255
1,605
437
139
1,151
1,540
400
130
1,096
FL500
AB100
AB250
AB500
FL100
FL250
FL500
175
1,600
0.5
2.0
800
3,200
766
760
3,200
2,986
2,919
2,615
2,402
2,143
1,180
1,004
800
3,200
3,056
2,989
2,780
2,747
2,540
2,327
2,281
2,028
1,143
968
800
3,200
3,126
1.85
1.85
1.76
1.63
1.59
1.40
1.26
1.10
0.50
2.00
1.87
1.79
1.70
1.65
1.52
1.50
1.37
1.24
1.21
1.05
0.50
2.00
1.89
1.81
1.76
Projected Cover - weeks

1.05
0.59
2.44
0.96
1.05
0.72
2.44
0.95
0.96
0.63
2.35
0.87
0.83
0.50
2.22
0.73
0.78
2.00
2.17
0.69
0.59
1.81
1.98
0.50
0.46
1.68
1.85
2.00
2.00
1.52
1.69
1.84
1.40
0.91
1.09
1.24
1.29
0.80
0.98
1.13
1.16
0.68
0.85
1.00
1.07
0.59
0.76
0.91
0.98
0.50
0.67
0.82
0.94
2.00
0.63
0.78
0.81
1.87
0.50
0.65
0.79
1.85
2.00
0.63
0.66
1.72
1.87
0.50
0.53
1.59
1.74
2.00
0.50
1.56
1.71
1.97
2.00
1.40
1.55
1.81
1.45
0.85
1.00
1.26
1.34
0.74
0.89
1.15
1.23
0.63
0.78
1.05
1.15
0.55
0.70
0.96
1.10
0.50
0.65
0.91
Lowest Offs
Cover
et
0.48
0.48
2.00
1.87
1.82
1.63
1.50
1.34
0.74
0.63
0.50
2.00
1.91
1.87
1.74
1.72
1.59
1.45
1.43
1.27
0.71
0.61
0.50
2.00
1.95
0.48
0.63
0.50
0.69
0.50
0.46
1.10
0.50
0.63
0.50
0.59
0.50
0.63
0.50
0.63
0.50
0.53
0.50
1.05
0.50
0.61
0.50
0.55
0.50
Projected Inventory
Cover
3.0
2.5
Weeks
2.0
AB100
1.5
1.0
0.5
0.0
10-Mar
15-Mar
20-Mar
25-Mar
30-Mar
4-Apr
9-Apr
AB250
AB500
FL100
FL250
FL500
Next
Prod
6 FL500
3 AB500
3 AB500
5 FL250
5 FL250
2 AB250
1 AB100
1 AB100
6 FL500
6 FL500
3 AB500
3 AB500
4 FL100
4 FL100
5 FL250
5 FL250
2 AB250
2 AB250
1 AB100
1 AB100
6 FL500
6 FL500
3 AB500
3 AB500
Invento
ry
Speed
760
507
400
828
600
644
1102
500
1004
800
472
400
126
100
755
600
740
700
1053
500
968
800
437
400
175
175
175
87.5
87.5
87.5
87.5
87.5
175
175
175
175
87.5
87.5
87.5
87.5
87.5
87.5
87.5
87.5
175
175
175
175
Forcast
1600
800
800
1200
1200
1400
1000
1000
1600
1600
800
800
200
200
1200
1200
1400
1400
1000
1000
1600
1600
800
800
Min
Cover
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
Min
cartons
800
400
400
600
600
700
500
500
800
800
400
400
100
100
600
600
700
700
500
500
800
800
400
400
Max
cartons
3200
1600
1600
2400
2400
2800
2000
2000
3200
3200
1600
1600
400
400
2400
2400
2800
2800
2000
2000
3200
3200
1600
1600
To
make
2580
1124
1234
1712
1960
2383
964
1609
2322
2538
1160
1234
278
304
1791
1960
2276
2321
1016
1609
2360
2538
1196
1234
Make-to-Inventory Logic Explained

The logic works as follows:
- the first job is the "Product running now"
- it starts at the "Start of the first job"
- and the "Quantity committed" is specified
the
duration of the job is calculated from the speed, and shown in the "Run hours" column
a
separate
column for each product records the projected inventory level at the end of each job
at
the
end
of
each job, the inventory level of one product has risen, and the other four products have fallen
- the opening inventory is recorded at the top of the columns, and would typically come from an inventory
management system
- the inventory at the end of the job is the opening inventory, less the forecast sales for the duration of the
job, plus the production quantity of the job
- another bank of six columns expresses the projected inventory level as days of cover
- the product with the lowest cover at the end of the job is identified as the next product to be made
- the quantity to make is that required to increase the inventory level to the maximum, plus sufficient to
replenish the amount sold while the job was running
- the duration of the next job is calculated, and the cycle begins again
- if the projected inventory level of the lowest cover product is above its minimum, then an idle period is
scheduled
- the duration of the idle period is the time it will take for forecast sales to reduce the inventory to the
minimum and trigger the next run
You will see from the chart of inventory cover, that the model attempts to keep the inventory of each product
between the minimum and maximum.
This is a PivotTable of the Finite Schedule on the previous sheet.
For each product, it lists the start time, and numbers each production run.
Prod/Run
AB100/1
AB100/2
AB250/1
AB250/2
AB500/1
AB500/2
AB500/3
FL100/1
FL250/1
FL250/2
FL500/1
FL500/2
FL500/3
Prod
AB100
AB100
AB250
AB250
AB500
AB500
AB500
FL100
FL250
FL250
FL500
FL500
FL500
Sum of Qty
Product
Start
Total
AB100
### 1609
4/4/2000 1:47 1609
AB250
### 2383
3/30/2000 2:21 2321
AB500
3/14/2000 8:00
110
### 1234
### 1234
FL100
###
304
FL250
### 1960
### 1960
FL500
3/14/2000 8:37 2580
### 2538
4/5/2000 13:49 2538
Grand Total
22380
Run
1
2
1
2
1
2
3
1
1
2
1
2
3
This sheet allows for 3 production runs of each product. The Bill of Materials is repeated 3 times,
and the quantities of each component required for each production run, is calculated.
Product/
Run
AB100/1
AB100/1
AB100/1
AB100/1
AB100/1
AB100/1
AB250/1
AB250/1
AB250/1
AB250/1
AB250/1
AB250/1
AB500/1
AB500/1
AB500/1
AB500/1
AB500/1
AB500/1
FL100/1
FL100/1
FL100/1
FL100/1
FL100/1
FL100/1
FL250/1
FL250/1
FL250/1
FL250/1
FL250/1
FL250/1
FL500/1
FL500/1
FL500/1
FL500/1
FL500/1
FL500/1
/1
/1
/1
/1
/1
/1
/1
/1
/1
/1
AB100/2
AB100/2
AB100/2
AB100/2
Component
BS01
BT100
CAPF
CARS
ESA
LAB10
BS01
BT250
CAPF
CARL
ESA
LAB25
BS01
BT500
CAPS
CARL
ESA
LAB50
BS01
BT100
CAPF
CARS
ESL
LFL10
BS01
BT250
CAPF
CARL
ESL
LFL25
BS01
BT500
CAPS
CARL
ESL
LFL50
0
0
0
0
0
0
0
0
0
0
BS01
BT100
CAPF
CARS
Component
Qty Production
Production Quantity
each Run Index Start Date
Qty
Required
4.8
6 23-Mar-00
1609
7723.2
48
6 23-Mar-00
1609
77232
48
6 23-Mar-00
1609
77232
1
6 23-Mar-00
1609
1609
0.05
6 23-Mar-00
1609
77.23
50
6 23-Mar-00
1609
80450
12
8 18-Mar-00
2383
28596
48
8 18-Mar-00
2383
114384
48
8 18-Mar-00
2383
114384
1
8 18-Mar-00
2383
2383
0.12
8 18-Mar-00
2383
285.96
50
8 18-Mar-00
2383
119150
12
10 14-Mar-00
110
1320
24
10 14-Mar-00
110
2640
24
10 14-Mar-00
110
2640
1
10 14-Mar-00
110
110
0.12
10 14-Mar-00
110
13.2
26
10 14-Mar-00
110
2860
4.8
13 27-Mar-00
304
1459.2
48
13 27-Mar-00
304
14592
48
13 27-Mar-00
304
14592
1
13 27-Mar-00
304
304
0.05
13 27-Mar-00
304
14.59
50
13 27-Mar-00
304
15200
12
14 17-Mar-00
1960
23520
48
14 17-Mar-00
1960
94080
48
14 17-Mar-00
1960
94080
1
14 17-Mar-00
1960
1960
0.12
14 17-Mar-00
1960
235.2
50
14 17-Mar-00
1960
98000
12
16 14-Mar-00
2580
30960
24
16 14-Mar-00
2580
61920
24
16 14-Mar-00
2580
61920
1
16 14-Mar-00
2580
2580
0.12
16 14-Mar-00
2580
309.6
26
16 14-Mar-00
2580
67080
0
#N/A 30-Dec-99
0
0
0
#N/A 30-Dec-99
0
0
0
#N/A 30-Dec-99
0
0
0
#N/A 30-Dec-99
0
0
0
#N/A 30-Dec-99
0
0
0
#N/A 30-Dec-99
0
0
0
#N/A 30-Dec-99
0
0
0
#N/A 30-Dec-99
0
0
0
#N/A 30-Dec-99
0
0
0
#N/A 30-Dec-99
0
0
4.8
7 4-Apr-00
1609
7723.2
48
7 4-Apr-00
1609
77232
48
7 4-Apr-00
1609
77232
1
7 4-Apr-00
1609
1609
AB100/2
AB100/2
AB250/2
AB250/2
AB250/2
AB250/2
AB250/2
AB250/2
AB500/2
AB500/2
AB500/2
AB500/2
AB500/2
AB500/2
FL100/2
FL100/2
FL100/2
FL100/2
FL100/2
FL100/2
FL250/2
FL250/2
FL250/2
FL250/2
FL250/2
FL250/2
FL500/2
FL500/2
FL500/2
FL500/2
FL500/2
FL500/2
/2
/2
/2
/2
/2
/2
/2
/2
/2
/2
AB100/3
AB100/3
AB100/3
AB100/3
AB100/3
AB100/3
AB250/3
AB250/3
AB250/3
AB250/3
AB250/3
AB250/3
AB500/3
AB500/3
ESA
LAB10
BS01
BT250
CAPF
CARL
ESA
LAB25
BS01
BT500
CAPS
CARL
ESA
LAB50
BS01
BT100
CAPF
CARS
ESL
LFL10
BS01
BT250
CAPF
CARL
ESL
LFL25
BS01
BT500
CAPS
CARL
ESL
LFL50
0
0
0
0
0
0
0
0
0
0
BS01
BT100
CAPF
CARS
ESA
LAB10
BS01
BT250
CAPF
CARL
ESA
LAB25
BS01
BT500
0.05
50
12
48
48
1
0.12
50
12
24
24
1
0.12
26
4.8
48
48
1
0.05
50
12
48
48
1
0.12
50
12
24
24
1
0.12
26
0
0
0
0
0
0
0
0
0
0
4.8
48
48
1
0.05
50
12
48
48
1
0.12
50
12
24
7
7
9
9
9
9
9
9
11
11
11
11
11
11
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
15
15
15
15
15
15
17
17
17
17
17
17
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
12
12
4-Apr-00
4-Apr-00
30-Mar-00
30-Mar-00
30-Mar-00
30-Mar-00
30-Mar-00
30-Mar-00
15-Mar-00
15-Mar-00
15-Mar-00
15-Mar-00
15-Mar-00
15-Mar-00
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
28-Mar-00
28-Mar-00
28-Mar-00
28-Mar-00
28-Mar-00
28-Mar-00
25-Mar-00
25-Mar-00
25-Mar-00
25-Mar-00
25-Mar-00
25-Mar-00
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
26-Mar-00
26-Mar-00
1609
1609
2321
2321
2321
2321
2321
2321
1234
1234
1234
1234
1234
1234
0
0
0
0
0
0
1960
1960
1960
1960
1960
1960
2538
2538
2538
2538
2538
2538
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1234
1234
77.23
80450
27852
111408
111408
2321
278.52
116050
14808
29616
29616
1234
148.08
32084
0
0
0
0
0
0
23520
94080
94080
1960
235.2
98000
30456
60912
60912
2538
304.56
65988
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
14808
29616
AB500/3
AB500/3
AB500/3
AB500/3
FL100/3
FL100/3
FL100/3
FL100/3
FL100/3
FL100/3
FL250/3
FL250/3
FL250/3
FL250/3
FL250/3
FL250/3
FL500/3
FL500/3
FL500/3
FL500/3
FL500/3
FL500/3
/3
/3
/3
/3
/3
/3
/3
/3
/3
/3
CAPS
CARL
ESA
LAB50
BS01
BT100
CAPF
CARS
ESL
LFL10
BS01
BT250
CAPF
CARL
ESL
LFL25
BS01
BT500
CAPS
CARL
ESL
LFL50
0
0
0
0
0
0
0
0
0
0
24
1
0.12
26
4.8
48
48
1
0.05
50
12
48
48
1
0.12
50
12
24
24
1
0.12
26
0
0
0
0
0
0
0
0
0
0
12
12
12
12
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
18
18
18
18
18
18
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
26-Mar-00
26-Mar-00
26-Mar-00
26-Mar-00
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
5-Apr-00
5-Apr-00
5-Apr-00
5-Apr-00
5-Apr-00
5-Apr-00
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
30-Dec-99
1234
1234
1234
1234
0
0
0
0
0
0
0
0
0
0
0
0
2538
2538
2538
2538
2538
2538
0
0
0
0
0
0
0
0
0
0
29616
1234
148.08
32084
0
0
0
0
0
0
0
0
0
0
0
0
30456
60912
60912
2538
304.56
65988
0
0
0
0
0
0
0
0
0
0
Columns A to D are a PivotTable of the database on BOM x 3, and the rest are formulae.
At row 150 there are links to the Purchase Orders worksheet.
Here component inventory is allocated to the earliest production runs first.
2
Sum of Component Quantity Required
Item
ComponentStart Date Product/Run Total
Component
Start Date Index
Description
BS01
14-Mar-00 AB500/1
1320 BS01
14-Mar-00
13 Base Shampoo
FL500/1
30960 BS01
14-Mar-00
13 Base Shampoo
15-Mar-00 AB500/2
14808 BS01
15-Mar-00
13 Base Shampoo
17-Mar-00 FL250/1
23520 BS01
17-Mar-00
13 Base Shampoo
18-Mar-00 AB250/1
28596 BS01
18-Mar-00
13 Base Shampoo
23-Mar-00 AB100/1
7723.2 BS01
23-Mar-00
13 Base Shampoo
25-Mar-00 FL500/2
30456 BS01
25-Mar-00
13 Base Shampoo
26-Mar-00 AB500/3
14808 BS01
26-Mar-00
13 Base Shampoo
27-Mar-00 FL100/1
1459.2 BS01
27-Mar-00
13 Base Shampoo
28-Mar-00 FL250/2
23520 BS01
28-Mar-00
13 Base Shampoo
30-Mar-00 AB250/2
27852 BS01
30-Mar-00
13 Base Shampoo
4-Apr-00 AB100/2
7723.2 BS01
4-Apr-00
13 Base Shampoo
5-Apr-00 FL500/3
30456 BS01
5-Apr-00
13 Base Shampoo
BT100
23-Mar-00 AB100/1
77232 BT100
23-Mar-00
16 Bottle 100ml
27-Mar-00 FL100/1
14592 BT100
27-Mar-00
16 Bottle 100ml
4-Apr-00 AB100/2
77232 BT100
4-Apr-00
16 Bottle 100ml
BT250
17-Mar-00 FL250/1
94080 BT250
17-Mar-00
17 Bottle 250ml
18-Mar-00 AB250/1
114384 BT250
18-Mar-00
17 Bottle 250ml
28-Mar-00 FL250/2
94080 BT250
28-Mar-00
17 Bottle 250ml
30-Mar-00 AB250/2
111408 BT250
30-Mar-00
17 Bottle 250ml
BT500
14-Mar-00 AB500/1
2640 BT500
14-Mar-00
18 Bottle 500ml
FL500/1
61920 BT500
14-Mar-00
18 Bottle 500ml
15-Mar-00 AB500/2
29616 BT500
15-Mar-00
18 Bottle 500ml
25-Mar-00 FL500/2
60912 BT500
25-Mar-00
18 Bottle 500ml
26-Mar-00 AB500/3
29616 BT500
26-Mar-00
18 Bottle 500ml
5-Apr-00 FL500/3
60912 BT500
5-Apr-00
18 Bottle 500ml
CAPF
17-Mar-00 FL250/1
94080 CAPF
17-Mar-00
19 Flip cap
18-Mar-00 AB250/1
114384 CAPF
18-Mar-00
19 Flip cap
23-Mar-00 AB100/1
77232 CAPF
23-Mar-00
19 Flip cap
27-Mar-00 FL100/1
14592 CAPF
27-Mar-00
19 Flip cap
28-Mar-00 FL250/2
94080 CAPF
28-Mar-00
19 Flip cap
30-Mar-00 AB250/2
111408 CAPF
30-Mar-00
19 Flip cap
4-Apr-00 AB100/2
77232 CAPF
4-Apr-00
19 Flip cap
CAPS
14-Mar-00 AB500/1
2640 CAPS
14-Mar-00
20 Screw cap
FL500/1
61920 CAPS
14-Mar-00
20 Screw cap
15-Mar-00 AB500/2
29616 CAPS
15-Mar-00
20 Screw cap
25-Mar-00 FL500/2
60912 CAPS
25-Mar-00
20 Screw cap
26-Mar-00 AB500/3
29616 CAPS
26-Mar-00
20 Screw cap
5-Apr-00 FL500/3
60912 CAPS
5-Apr-00
20 Screw cap
CARL
14-Mar-00 AB500/1
110 CARL
14-Mar-00
28 Carton large
FL500/1
2580 CARL
14-Mar-00
28 Carton large
15-Mar-00 AB500/2
1234 CARL
15-Mar-00
28 Carton large
17-Mar-00 FL250/1
1960 CARL
17-Mar-00
28 Carton large
18-Mar-00 AB250/1
2383 CARL
18-Mar-00
28 Carton large
25-Mar-00 FL500/2
2538 CARL
25-Mar-00
28 Carton large
26-Mar-00 AB500/3
1234 CARL
26-Mar-00
28 Carton large
28-Mar-00 FL250/2
1960 CARL
28-Mar-00
28 Carton large
30-Mar-00 AB250/2
2321 CARL
30-Mar-00
28 Carton large
5-Apr-00 FL500/3
2538 CARL
5-Apr-00
28 Carton large
CARS
ESA
ESL
LAB10
LAB25
LAB50
LFL10
LFL25
LFL50
23-Mar-00 AB100/1
27-Mar-00 FL100/1
4-Apr-00 AB100/2
14-Mar-00 AB500/1
15-Mar-00 AB500/2
18-Mar-00 AB250/1
23-Mar-00 AB100/1
26-Mar-00 AB500/3
30-Mar-00 AB250/2
4-Apr-00 AB100/2
14-Mar-00 FL500/1
17-Mar-00 FL250/1
25-Mar-00 FL500/2
27-Mar-00 FL100/1
28-Mar-00 FL250/2
5-Apr-00 FL500/3
23-Mar-00 AB100/1
4-Apr-00 AB100/2
18-Mar-00 AB250/1
30-Mar-00 AB250/2
14-Mar-00 AB500/1
15-Mar-00 AB500/2
26-Mar-00 AB500/3
27-Mar-00 FL100/1
17-Mar-00 FL250/1
28-Mar-00 FL250/2
14-Mar-00 FL500/1
25-Mar-00 FL500/2
5-Apr-00 FL500/3
1609 CARS
304 CARS
1609 CARS
13.2 ESA
148.08 ESA
285.96 ESA
77.23 ESA
148.08 ESA
278.52 ESA
77.23 ESA
309.6 ESL
235.2 ESL
304.56 ESL
14.59 ESL
235.2 ESL
304.56 ESL
80450 LAB10
80450 LAB10
119150 LAB25
116050 LAB25
2860 LAB50
32084 LAB50
32084 LAB50
15200 LFL10
98000 LFL25
98000 LFL25
67080 LFL50
65988 LFL50
65988 LFL50
23-Mar-00
27-Mar-00
4-Apr-00
14-Mar-00
15-Mar-00
18-Mar-00
23-Mar-00
26-Mar-00
30-Mar-00
4-Apr-00
14-Mar-00
17-Mar-00
25-Mar-00
27-Mar-00
28-Mar-00
5-Apr-00
23-Mar-00
4-Apr-00
18-Mar-00
30-Mar-00
14-Mar-00
15-Mar-00
26-Mar-00
27-Mar-00
17-Mar-00
28-Mar-00
14-Mar-00
25-Mar-00
5-Apr-00
27 Carton small
27 Carton small
27 Carton small
14 Apple essence
14 Apple essence
14 Apple essence
14 Apple essence
14 Apple essence
14 Apple essence
14 Apple essence
15 Lemon essence
15 Lemon essence
15 Lemon essence
15 Lemon essence
15 Lemon essence
15 Lemon essence
21 Label Apple Blossom 100ml
24 Label Fragrant Lemon 100ml
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
BS01
BS01
BT100
BT250
BT250
BT250
BT500
BT500
BT500
CAPF
CAPF
CAPS
CAPS
CARL
CARL
CARS
CARS
ESA
18-Mar-00
30-Mar-00
14-Apr-00
18-Mar-00
1-Apr-00
22-Apr-00
16-Mar-00
1-Apr-00
15-Apr-00
16-Mar-00
7-Apr-00
17-Mar-00
2-Apr-00
14-Mar-00
4-Apr-00
18-Mar-00
26-Apr-00
23-Mar-00
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
Base Shampoo
Base Shampoo
Bottle 100ml
Bottle 250ml
Bottle 250ml
Bottle 250ml
Bottle 500ml
Bottle 500ml
Bottle 500ml
Flip cap
Flip cap
Screw cap
Screw cap
Carton large
Carton large
Carton small
Carton small
Apple essence
ESA
ESL
LAB10
LAB25
LAB25
LAB50
LAB50
LAB50
LFL10
LFL10
LFL25
LFL25
LFL50
LFL50
6-Apr-00
3-Apr-00
7-Apr-00
14-Mar-00
21-Mar-00
2-Apr-00
16-Apr-00
30-Apr-00
14-Apr-00
28-Apr-00
17-Mar-00
31-Mar-00
30-Mar-00
13-Apr-00
Apple essence
Lemon essence
Supplier
AC01
AC01
AC01
AC01
AC01
AC01
AC01
AC01
AC01
AC01
AC01
AC01
AC01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
EC01
EC01
EC01
EC01
EC01
EC01
EC01
EC01
EC01
EC01
Balance
Supplier Name
Inventory Remaining Get In
On order
Ace Chemicals
34,276
32,956
0
Ace Chemicals
34,276
1,996
0
Ace Chemicals
34,276
-12,812
12,812
Ace Chemicals
34,276
-36,332
23,520
Ace Chemicals
34,276
-64,928
28,596
Ace Chemicals
34,276
-72,651
7,723
Ace Chemicals
34,276
-103,107
30,456
Ace Chemicals
34,276
-117,915
14,808
Ace Chemicals
34,276
-119,374
1,459
Ace Chemicals
34,276
-142,894
23,520
Ace Chemicals
34,276
-170,746
27,852
Ace Chemicals
34,276
-178,470
7,723
Ace Chemicals
34,276
-208,926
30,456
Best Plastics
122,472
45,240
0
Best Plastics
122,472
30,648
0
Best Plastics
122,472
-46,584
46,584
Best Plastics
184,968
90,888
0
Best Plastics
184,968
-23,496
23,496
Best Plastics
184,968
-117,576
94,080
Best Plastics
184,968
-228,984 111,408
Best Plastics
36,516
33,876
0
Best Plastics
36,516
-28,044
28,044
Best Plastics
36,516
-57,660
29,616
Best Plastics
36,516
-118,572
60,912
Best Plastics
36,516
-148,188
29,616
Best Plastics
36,516
-209,100
60,912
Best Plastics
65,738
-28,342
28,342
Best Plastics
65,738
-142,726 114,384
Best Plastics
65,738
-219,958
77,232
Best Plastics
65,738
-234,550
14,592
Best Plastics
65,738
-328,630
94,080
Best Plastics
65,738
-440,038 111,408
Best Plastics
65,738
-517,270
77,232
Best Plastics
37,818
35,178
0
Best Plastics
37,818
-26,742
26,742
Best Plastics
37,818
-56,358
29,616
Best Plastics
37,818
-117,270
60,912
Best Plastics
37,818
-146,886
29,616
Best Plastics
37,818
-207,798
60,912
Eduardo Corrugates
4,368
4,258
0
Eduardo Corrugates
4,368
1,678
0
Eduardo Corrugates
4,368
444
0
Eduardo Corrugates
4,368
-1,516
1,516
Eduardo Corrugates
4,368
-3,899
2,383
Eduardo Corrugates
4,368
-6,437
2,538
Eduardo Corrugates
4,368
-7,671
1,234
Eduardo Corrugates
4,368
-9,631
1,960
Eduardo Corrugates
4,368
-11,952
2,321
Eduardo Corrugates
4,368
-14,490
2,538
EC01
EC01
EC01
CE01
CE01
CE01
CE01
CE01
CE01
CE01
CE01
CE01
CE01
CE01
CE01
CE01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
Eduardo Corrugates
Eduardo Corrugates
Eduardo Corrugates
Chang Essences
Chang Essences
Chang Essences
Chang Essences
Chang Essences
Chang Essences
Chang Essences
Chang Essences
Chang Essences
Chang Essences
Chang Essences
Chang Essences
Chang Essences
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
998
998
998
1,494
1,494
1,494
1,494
1,494
1,494
1,494
1,002
1,002
1,002
1,002
1,002
1,002
211,796
211,796
266,776
266,776
24,964
24,964
24,964
32,140
83,496
83,496
117,354
117,354
117,354
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
-611
-915
-2,524
1,481
1,333
1,047
970
821
543
466
692
457
153
138
-97
-402
131,346
50,896
147,626
31,576
22,104
-9,980
-42,064
16,940
-14,504
-112,504
50,274
-15,714
-81,702
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
611
304
1,609
0
0
0
0
0
0
0
0
0
0
0
97
305
0
0
0
0
0
9,980
32,084
0
14,504
98,000
0
15,714
65,988
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
AC01
AC01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
BP01
EC01
EC01
EC01
EC01
CE01
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
Ace Chemicals
Ace Chemicals
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Best Plastics
Eduardo Corrugates
Eduardo Corrugates
Eduardo Corrugates
Eduardo Corrugates
Chang Essences
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
100,000
100,000
40,000
90,000
40,000
50,000
100,000
50,000
50,000
200,000
300,000
100,000
100,000
8,000
5,000
1,000
1,000
60
CE01
CE01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
DP01
Chang Essences
Chang Essences
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
Dave's Printing
100
350
50,000
70,000
60,000
20,000
20,000
20,000
10,000
10,000
60,000
60,000
40,000
40,000
Supplier Name Description
Start Date
3/15/2000
3/17/2000
Base Shampoo
Ace Chemicals
3/18/2000
3/23/2000
3/25/2000
3/26/2000
3/27/2000
3/28/2000
3/30/2000
3/18/2000
Bottle 500ml
3/28/2000
3/30/2000
4/1/2000
4/22/2000
Bottle 250ml Total
3/14/2000
3/15/2000
3/16/2000
3/25/2000
3/26/2000
4/1/2000
4/5/2000
4/15/2000
Bottle 500ml Total
3/16/2000
3/17/2000
3/18/2000
3/23/2000
3/27/2000
3/28/2000
3/30/2000
4/4/2000
4/7/2000
Flip cap Total
3/14/2000
3/15/2000
3/17/2000
3/25/2000
3/26/2000
4/2/2000
4/5/2000
Screw cap Total
Screw cap
Flip cap
Best Plastics
Bottle 250ml
Bottl
e
100
ml
4/4/2000
4/5/2000
Base Shampoo Total
4/4/2000
4/14/2000
Bottle 100ml Total
Product/Run
AB500/2
FL250/1
AB250/1
AB100/1
FL500/2
AB500/3
FL100/1
FL250/2
AB250/2
AB100/2
FL500/3
AB100/2
AB250/1
FL250/2
AB250/2
FL500/1
AB500/2
FL500/2
AB500/3
FL500/3
FL250/1
AB250/1
AB100/1
FL100/1
FL250/2
AB250/2
AB100/2
FL500/1
AB500/2
FL500/2
AB500/3
FL500/3
Data
Get In
On order
12,812
23,520
28,596
100,000
7,723
30,456
14,808
1,459
23,520
27,852
100,000
7,723
30,456
208,926 200,000
46,584
40,000
46,584
40,000
23,496
90,000
94,080
111,408
40,000
50,000
228,984 180,000
28,044
29,616
100,000
60,912
29,616
50,000
60,912
50,000
209,100 200,000
200,000
28,342
114,384
77,232
14,592
94,080
111,408
77,232
300,000
517,270 500,000
26,742
29,616
100,000
60,912
29,616
100,000
60,912
207,798 200,000
Balance
-12,812
-36,332
-64,928
35,072
27,349
-3,107
-17,915
-19,374
-42,894
-70,746
29,254
21,530
-8,926
0
-46,584
-6,584
0
-23,496
66,504
-27,576
-138,984
-98,984
-48,984
0
-28,044
-57,660
42,340
-18,572
-48,188
1,812
-59,100
-9,100
0
200,000
171,658
57,274
-19,958
-34,550
-128,630
-240,038
-317,270
-17,270
0
-26,742
-56,358
43,642
-17,270
-46,886
53,114
-7,798
0
Page 25 of 33

Data
Get In
Lemon
essenc
e
Appl
e
esse
nce
Start Date Product/Run

3/23/2000
4/6/2000
Apple essence Total
3/28/2000
FL250/2
4/3/2000
4/5/2000
FL500/3
Lemon essence Total
4/7/2000
Label Apple Blossom 100ml Total
3/14/2000
3/21/2000
3/15/2000
AB500/2
3/26/2000
AB500/3
4/2/2000
4/16/2000
4/30/2000
4/14/2000
4/28/2000
Label Fragrant Lemon 100ml Total
FL250/1
3/17/2000
350
305
402
Lab
el
Appl
e
Blos
som
250
ml
Label Apple
Blossom
500ml
Carton large
Carton small
350
50,000
50,000
70,000
60,000
130,000
9,980
32,084
42,064
Lab
el
Frag
rant
Lem
on
100
ml
Label
Fragrant
Lemon
250ml
Dave's Printing
Eduardo Corrugates
Label
Fragrant
Lemon
500ml
3/28/2000
FL250/2
3/31/2000
3/25/2000
FL500/2
3/30/2000
4/5/2000
FL500/3
4/13/2000
3/14/2000
3/17/2000
FL250/1
3/18/2000
AB250/1
3/25/2000
FL500/2
3/26/2000
AB500/3
3/28/2000
FL250/2
3/30/2000
AB250/2
4/4/2000
4/5/2000
FL500/3
Carton large Total
3/18/2000
3/23/2000
AB100/1
3/27/2000
FL100/1
4/4/2000
AB100/2
4/26/2000
Carton small Total
Balance
On order
60
100
160
97
L
a
b
el
A
p
pl
e
Bl
o
s
s
o
m
1
0
0
m
l
Chang Essences
Supplier Name Description
20,000
20,000
20,000
60,000
10,000
10,000
20,000
14,504
60,000
98,000
112,504
15,714
60,000
120,000
40,000
65,988
81,702
40,000
80,000
8,000
1,516
2,383
2,538
1,234
1,960
2,321
5,000
2,538
14,490
13,000
1,000
611
304
1,609
2,524
1,000
2,000
60
160
0
-97
253
-52
0
50,000
0
70,000
130,000
0
-9,980
-42,064
-22,064
-2,064
17,936
0
10,000
20,000
0
-14,504
45,496
-52,504
7,496
0
-15,714
24,286
-41,702
-1,702
0
8,000
6,484
4,101
1,563
329
-1,631
-3,952
1,048
-1,490
0
1,000
389
85
-1,524
-524
0
Page 26 of 33
Inventory rationing addresses a question that many manufacturers have:
"What products should I make with the inventory I have on hand right now?"
The system takes into account raw materials that are used by more than one product, and rations the
inventory across the products so as to even out the product inventory cover as much as possible.
You will see that On the Inventory Rationing Calculation sheet, there are 3 groups of columns:
- Bill of Materials
- First Pass Calculations
- Second Pass Calculations
The bill of materials data is repeated in the first 4 columns.
The finished product inventory and forecast is used to calculate finished product inventory cover. In other
words, how many weeks the finished product inventory will last if sales are according to forecast.
Imagine that all the finished products in inventory are broken down to their component parts, and "pooled"
by being put back into the raw material warehouse, and added to the component inventory that has not
yet been used. The forecast usage of each component is then calculated from the sales forecast of the
products they are used on, times the quantity used in each case of product. From this, the average cover
of each component is calculated.
Finished products which have a cover above the average, then have their components and their forecast
eliminated from the calculation, and the average is re-calculated. The quantity of each product that can
be made is constrained by the component with the lowest average cover. Components are alloacted to
products on that basis, the new projected inventories of products and components are calculated, and the
Second Pass Calculations repeat the logic again to determinte what products could be made with the
components that are left over.
The calculation involves circular, iterative references as follows:
F
P
Inventory
Rationing
Calculation
Components
Pivot
P
Products Pivot
F
Formula link:
PivotTable link:
F
P
After a change, click on the Refresh All icon

several times, until the data stops changing.
Put the Refresh All icon on you toolbar by right clicking on the toolbar, then Cutomise|Commands|Data
find the icon and drag it up onto your toolbar
8
Bill of Materials
Product
AB100
AB100
AB100
AB100
AB100
AB100
AB250
AB250
AB250
AB250
AB250
AB250
AB500
AB500
AB500
AB500
AB500
AB500
FL100
FL100
FL100
FL100
FL100
FL100
FL250
FL250
FL250
FL250
FL250
FL250
FL500
FL500
FL500
FL500
FL500
FL500
Component Qty
Component Description
BS01
4.800 Base Shampoo
BT100
48.000 Bottle 100ml
CAPF
48.000 Flip cap
CARS
1.000 Carton small
ESA
0.048 Apple essence
LAB10
BS01
12.000 Base Shampoo
BT250
48.000 Bottle 250ml
CAPF
48.000 Flip cap
CARL
1.000 Carton large
ESA
0.120 Apple essence
LAB25
BS01
12.000 Base Shampoo
BT500
24.000 Bottle 500ml
CAPS
24.000 Screw cap
CARL
1.000 Carton large
ESA
0.120 Apple essence
LAB50
BS01
4.800 Base Shampoo
BT100
48.000 Bottle 100ml
CAPF
48.000 Flip cap
CARS
1.000 Carton small
ESL
0.048 Lemon essence
LFL10
BS01
12.000 Base Shampoo
BT250
48.000 Bottle 250ml
CAPF
48.000 Flip cap
CARL
1.000 Carton large
ESL
0.120 Lemon essence
LFL25
BS01
12.000 Base Shampoo
BT500
24.000 Bottle 500ml
CAPS
24.000 Screw cap
CARL
1.000 Carton large
ESL
0.120 Lemon essence
LFL50
8
First Pass Calculations
Product
Product
Total
Total
Total
Product
Sales
Inventory Component Component
Components Components Average
Cover
Min
Forcast
Product
Cover Sales Forcast
Sales
Components
in Product
in Product
Inventory
Below
Average Make
per Week Inventory Weeks
per Week
Forecast
in Inventory
Inventory
Inventory
Cover
Average
Cover Weeks
1000
1854
1.85
0
60000
34276
0
46248
1.34
FALSE
1.34
0.00
1000
1854
1.85
48000
57600
122472
88992
112416
4.08
TRUE
1.34
0.00
1000
1854
1.85
0
124800
65738
0
125664
1.53
FALSE
1.34
0.00
1000
1854
1.85
0
1000
998
0
488
1.49
FALSE
1.34
0.00
1000
1854
1.85
48
312
1494
89
322
5.82
TRUE
1.34
0.00
1000
1854
1.85
50000
50000
211796
92700
92700
6.09
TRUE
1.34
0.00
1400
1470
1.05
16800
60000
34276
17640
46248
1.34
TRUE
1.34
0.29
1400
1470
1.05
67200
124800
184968
70560
125664
2.49
TRUE
1.34
0.29
1400
1470
1.05
67200
124800
65738
70560
125664
1.53
TRUE
1.34
0.29
1400
1470
1.05
1400
5000
4368
1470
3854
1.64
TRUE
1.34
0.29
1400
1470
1.05
168
312
1494
176
322
5.82
TRUE
1.34
0.29
1400
1470
1.05
70000
70000
266776
73500
73500
4.86
TRUE
1.34
0.29
800
470
0.59
9600
60000
34276
5640
46248
1.34
TRUE
1.15
0.56
800
470
0.59
19200
57600
36516
11280
29664
1.15
TRUE
1.15
0.56
800
470
0.59
19200
57600
37818
11280
29664
1.17
TRUE
1.15
0.56
800
470
0.59
800
5000
4368
470
3854
1.64
TRUE
1.15
0.56
800
470
0.59
96
312
1494
56
322
5.82
TRUE
1.15
0.56
800
470
0.59
20800
20800
24964
12220
12220
1.79
TRUE
1.15
0.56
200
488
2.44
0
60000
34276
0
46248
1.34
FALSE
1.34
0.00
200
488
2.44
9600
57600
122472
23424
112416
4.08
TRUE
1.34
0.00
200
488
2.44
0
124800
65738
0
125664
1.53
FALSE
1.34
0.00
200
488
2.44
200
200
998
488
488
7.43
TRUE
1.34
0.00
200
488
2.44
9.6
345.6
1002
23
253
3.63
TRUE
1.34
0.00
200
488
2.44
10000
10000
32140
24400
24400
5.65
TRUE
1.34
0.00
1200
1148
0.96
14400
60000
34276
13776
46248
1.34
TRUE
1.34
0.39
1200
1148
0.96
57600
124800
184968
55104
125664
2.49
TRUE
1.34
0.39
1200
1148
0.96
57600
124800
65738
55104
125664
1.53
TRUE
1.34
0.39
1200
1148
0.96
1200
5000
4368
1148
3854
1.64
TRUE
1.34
0.39
1200
1148
0.96
144
345.6
1002
138
253
3.63
TRUE
1.34
0.39
1200
1148
0.96
60000
60000
83496
57400
57400
2.35
TRUE
1.34
0.39
1600
766
0.48
19200
60000
34276
9192
46248
1.34
TRUE
1.15
0.67
1600
766
0.48
38400
57600
36516
18384
29664
1.15
TRUE
1.15
0.67
1600
766
0.48
38400
57600
37818
18384
29664
1.17
TRUE
1.15
0.67
1600
766
0.48
1600
5000
4368
766
3854
1.64
TRUE
1.15
0.67
1600
766
0.48
192
345.6
1002
92
253
3.63
TRUE
1.15
0.67
1600
766
0.48
41600
41600
117354
19916
19916
3.30
TRUE
1.15
0.67
Product
Make
Use
Total Use Inventory
Product Component Component
2
0
0
28714
1854
0
0
0
1854
0
0
41826
1854
0
0
0
1854
0
0
103
1854
0
0
0
1854
408.89
4906.72
28714 1878.89
408.89
19626.88
41826 1878.89
408.89
19626.88
41826 1878.89
408.89
408.89
2393 1878.89
408.89
49.07
103 1878.89
408.89
20444.67
20445 1878.89
449.17
5390
28714
919.17
449.17
10780
36516
919.17
449.17
10780
36516
919.17
449.17
449.17
2393
919.17
449.17
53.9
103
919.17
449.17
11678.33
11678
919.17
0
0
28714
488
0
0
0
488
0
0
41826
488
0
0
0
488
0
0
184
488
0
0
0
488
462.48
5549.76
28714 1610.48
462.48
22199.04
41826 1610.48
462.48
22199.04
41826 1610.48
462.48
462.48
2393 1610.48
462.48
55.5
184 1610.48
462.48
23124
23124 1610.48
1072.33
12868
28714 1838.33
1072.33
25736
36516 1838.33
1072.33
25736
36516 1838.33
1072.33
1072.33
2393 1838.33
1072.33
128.68
184 1838.33
1072.33
27880.67
27881 1838.33
Compone
Product Component
Total
Compone
nts in
Inventory
Sales
Compone
nts in
Product
Cover
Forcast per nt Sales Inventory Inventory
Weeks 2
Week 2 Forecast 2
2
2
1.85
0
4800
5562
0
1.85
0
48000
122472
0
1.85
0
48000
23912
0
1.85
0
1000
998
0
1.85
0
48
1391
0
1.85
0
50000
211796
0
1.34
0
16800
5562
0
1.34
0
67200
143142
0
1.34
0
67200
23912
0
1.34
0
1400
1975
0
1.34
0
168
1391
0
1.34
0
70000
246331
0
1.15
0
9600
5562
0
1.15
0
19200
0
0
1.15
0
19200
1302
0
1.15
0
800
1975
0
1.15
0
96
1391
0
1.15
0
20800
13286
0
2.44
960
960
5562
2342.4
2.44
9600
9600
122472
23424
2.44
9600
9600
23912
23424
2.44
200
200
998
488
2.44
9.6
9.6
818
23.42
2.44
10000
10000
32140
24400
1.34
0
14400
5562
0
1.34
0
57600
143142
0
1.34
0
57600
23912
0
1.34
0
1200
1975
0
1.34
0
144
818
0
1.34
0
60000
60372
0
1.15
0
19200
5562
0
1.15
0
38400
0
0
1.15
0
38400
1302
0
1.15
0
1600
1975
0
1.15
0
192
818
0
1.15
0
41600
89473
0
Second Pass Calculations

Total
Compone
nts in
Total
Product
Compone
Product Average
Cover
Min
Use
Total Use
nts in
Inventory Inventory
Below
Average
Make
Make
Compone Compone Inventory
2
Cover 2 Average 2 Cover 2 Weeks 2 Product 2
nt 2
nt 2
3
2342.4
1.65
FALSE
0.99
0.00
0
0 2391.21
3170
23424
3.04
FALSE
0.99
0.00
0
0 23912.08
98560
23424
0.99
FALSE
0.99
0.00
0
0 23912.08
0
488
1.49
FALSE
0.99
0.00
0
0
498.17
500
0
28.98
FALSE
0.99
0.00
0
0
0
1391
0
4.24
FALSE
0.99
0.00
0
0
0
211796
2342.4
0.47
FALSE
0.47
0.00
0
0 2391.21
3170
0
2.13
FALSE
0.47
0.00
0
0
0
143142
23424
0.70
FALSE
0.47
0.00
0
0 23912.08
0
0
1.41
FALSE
0.47
0.00
0
0
0
1975
0
8.28
FALSE
0.47
0.00
0
0
0
1391
0
3.52
FALSE
0.47
0.00
0
0
0
246331
2342.4
0.82
FALSE
0.00
0.00
0
0 2391.21
3170
0
0.00
FALSE
0.00
0.00
0
0
0
0
0
0.07
FALSE
0.00
0.00
0
0
0
1302
0
2.47
FALSE
0.00
0.00
0
0
0
1975
0
14.49
FALSE
0.00
0.00
0
0
0
1391
0
0.64
FALSE
0.00
0.00
0
0
0
13286
2342.4
8.23
TRUE
4.93
2.49
498.17 2391.21 2391.21
3170
23424
15.20
TRUE
4.93
2.49
498.17 23912.08 23912.08
98560
23424
4.93
TRUE
4.93
2.49
498.17 23912.08 23912.08
0
488
7.43
TRUE
4.93
2.49
498.17
498.17
498.17
500
23.42
87.63
TRUE
4.93
2.49
498.17
23.91
23.91
794
24400
5.65
TRUE
4.93
2.49
498.17 24908.42 24908.42
7232
2342.4
0.55
FALSE
0.55
0.00
0
0 2391.21
3170
0
2.49
FALSE
0.55
0.00
0
0
0
143142
23424
0.82
FALSE
0.55
0.00
0
0 23912.08
0
0
1.65
FALSE
0.55
0.00
0
0
0
1975
23.42
5.84
FALSE
0.55
0.00
0
0
23.91
794
0
1.01
FALSE
0.55
0.00
0
0
0
60372
2342.4
0.41
FALSE
0.00
0.00
0
0 2391.21
3170
0
0.00
FALSE
0.00
0.00
0
0
0
0
0
0.03
FALSE
0.00
0.00
0
0
0
1302
0
1.23
FALSE
0.00
0.00
0
0
0
1975
23.42
4.38
FALSE
0.00
0.00
0
0
23.91
794
0
2.15
FALSE
0.00
0.00
0
0
0
89473
Make
Product
1+2
0
0
0
0
0
0
409
409
409
409
409
409
449
449
449
449
449
449
498
498
498
498
498
498
462
462
462
462
462
462
1072
1072
1072
1072
1072
1072
Data
Sum of
Sum of
Sum of
Sum of
Component Components
Component Components in
Sales Forcast in Product
Sum of Use Sales Forcast
Product
Sum of Use
Component
per Week
Inventory
Component
per Week 2
Inventory 2
Component 2
BS01
60000
46248
28714.48
960
2342.4
2391.21
BT100
57600
112416
0
9600
23424
23912.08
BT250
124800
125664
41825.92
0
0
0
BT500
57600
29664
36516
0
0
0
CAPF
124800
125664
41825.92
9600
23424
23912.08
CAPS
57600
29664
36516
0
0
0
CARL
5000
3854
2392.87
0
0
0
CARS
200
488
0
200
488
498.17
ESA
312
321.79
102.97
0
0
0
ESL
345.6
253.1
184.18
9.6
23.42
23.91
LAB10
50000
92700
0
0
0
0
LAB25
70000
73500
20444.67
0
0
0
LAB50
20800
12220
11678.33
0
0
0
LFL10
10000
24400
0
10000
24400
24908.42
LFL25
60000
57400
23124
0
0
0
LFL50
41600
19916
27880.67
0
0
0
Data
Product
AB100
AB250
AB500
FL100
FL250
FL500
Min of Total
Min of Total
Average
Average
Inventory
Inventory
Cover
Cover 2
1.34
0.99
1.34
0.47
1.15
0
1.34
4.93
1.34
0.55
1.15
0
Product to
make with
components
in inventory
0
2454
2694
2988
2772
6432

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Inventory Rationing Calculations

Purchase Action Report

Bottles per Carton

Forecast Cartons per Week

C link and MS Query.

Speed - cartons per hour

Projected Inventory - units

Projected Cover - weeks

Make-to-Inventory Logic Explained

Purchase Action Report

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Purchase Action Report

Start Date Product/Run

Supplier Name Description

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Second Pass Calculations

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