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http://www.production-scheduling.com

Thank you for downloading this copy of Excel-Based MRP, I hope it will be of use to you.

You may also be interested in our model system for DRP/MRP/Capacity Scheduling

a Flash presentation that runs for 30 minutes

Why Excel-Based MRP?

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

Or visit our web site:

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?"

It handles multi-level bills of material - click on the link below:

http://www.production-scheduling.com/P-S_Cycles_Flash/viewer.swf

Production-Scheduling.com assists manufacturers to develop their own finite scheduling systems in Excel, andwill also custom develop scheduling systems for them. Most of these systems are interfaced to a host MRP/ERPsystem, which acts as a repository for demand and inventory data, and will perform Material RequirementsPlanning (MRP1) calculations.

This is a simple example of an MRP system, with a small amount of sample data, but it will also cater for manythousands of records.

If you need assistance to adapt the system to your own manufacturing process, please do not hesitate tocontact me, Tony Rice at:

[email protected]

www.Production-Scheduling.com

The system takes into account raw materials that are used by more than one product, and rations the inventoryacross the products so as to even out the product inventory cover as much as possible.


mailto:[email protected]

http://www.production-scheduling.com/


mailto:[email protected]


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EXCEL-BASED MRP

TABLE OF CONTENTS

DATA FILES:

MRP CALCULATIONS:

INVENTORY RATIONING:


INTRODUCTION

TABLE OF LINKS

THE BUSINESS

Item Master

Supplier Master

Bill of Materials (BOM)

Purchase Orders

FINITE SCHEDULE

Make-to-Inventory Logic Explained

Production Runs

BOM x 3

Allocate Inventory

Purchase Action Report

Inventory Rationing Logic

Inventory Rationing Calculations

Components Pivot

Products Pivot

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Table of Links

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.

T h e B u s i n e s s

I t e m M a s t e r

S u p p l i e r M a s t e r

B i l l o f M a t e r i a l

P u r c h a s e O r d e r s

F i n i t e S c h e d u l e

P r o d u c t i o n R u n s

B O M x

3

A l l o c a t e I n v e n t o r y

P u r c h a s e A c t i o n R e p o r t

I n v e n t o r y R a t i o n i n g C a l c u l a t i o n s

C o m p o n e n t s P i v o t

P r o d u c t s P i v o t

The BusinessItem Master F

Supplier Master

Bill of Material F

Purchase Orders F F

Finite Schedule F F

Production Runs P

BOM x 3 F F

Allocate Inventory F F P

Purchase Action Report P

Inventory Rationing Calculations F F F F F

Components Pivot P

Products Pivot P

Formula link: F

PivotTable link: P

Chained PivotTables

Data flows from the Finite Schedule to the Purchase Action Report through a chain of links that includes

3 PivotTables:

Unlike formulas, PivotTables do not change automatically when the data is changed, they need to be refre

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 workb

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

Worksheet

Links to :

Finite

Schedule

Production

Runs

BOM x 3Allocate

Inventory

PurchaseAction

Report

PurchaseOrders

FP P P

F

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hed.

ok.

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Outline of the Business

This example is based in a fictional business that makes and sells shampoo.

Product Range

Code Description Bottles per Carton Forecast Cartons per Week

AB100 Apple Blossom 100ml 48 1000



FL100 Fragrant Lemon 100ml 48 200



The Process

Bill of Materials

Capacities

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:

We buy a base shampoo in bulk, pump it into a blending vessel, add either apple or lemonessence to it, stir it, pump it into a holding vessel from where it is fed to the filling line wherethe bottles are filled, labelled, shrink wrapped 6 together, packed into corrugated cartons,and stacked on pallets.

There is one base shampoo, two fragrances, three bottle sizes and six labels. The 100mland 250ml bottles are fitted with a flip top cap, and the 500ml bottle has a screw cap. The100ml bottles are packed 48 to a small carton, the 250ml is packed 48 in a large carton andthe 500ml uses the same carton but 24 to a carton. Two of the bottle labels are pasted onthe 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 buyis one carton, so that is the SKU (stock keeping unit).

Blending is quicker than filling, 100ml and 250ml bottles can be filled at 70 per minute, and500ml bottles at 40 per minute. To change the line from one bottle size to another takestime, but we shall ignore change over times in this example.

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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 M

Code Description Warehouse Supplier Supplier Name

AB100 Apple Blossom 100ml carton FP 01 #N/A



FL100 Fragrant Lemon 100ml carton FP 01 #N/A



BS01 Base Shampoo litre RM AC01 Ace Chemicals

ESA Apple essence litre RM CE01 Chang Essences

ESL Lemon essence litre RM CE01 Chang Essences

BT100 Bottle 100ml each RM BP01 Best Plastics

BT250 Bottle 250ml each RM BP01 Best PlasticsBT500 Bottle 500ml each RM BP01 Best Plastics

CAPF Flip cap each RM BP01 Best Plastics

CAPS Screw cap each RM BP01 Best Plastics

LAB10 Label Apple Blossom 100ml each RM DP01 Dave's Printing



LFL10 Label Fragrant Lemon 100ml each RM DP01 Dave's Printing



CARS Carton small each RM EC01 Eduardo Corrugates

CARL Carton large each RM EC01 Eduardo Corrugates

Unit of Measure

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Query.

Inventory

1,854

1,470

470

488

1,148

766

14 34,276

30 1,494

30 1,002

21 122,472

21 184,96821 36,516

21 65,738

21 37,818

7 211,796

7 266,776

7 24,964

7 32,140

7 83,496

7 117,354

21 998

21 4,368

Lead

TimeDays

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Supplier Master

Code Supplier Name

AC01 Ace Chemicals

BP01 Best Plastics

CE01 Chang EssencesDP01 Dave's Printing

EC01 Eduardo Corrugates

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Bill of Material

This is a typical structure of a single level bill of materials, describing the relationship between

products and components

Product Component Qty Component Description

AB100 BS01 4.800 Base Shampoo

AB100 BT100 48.000 Bottle 100ml

AB100 CAPF 48.000 Flip cap

AB100 CARS 1.000 Carton small

AB100 ESA 0.048 Apple essence

AB100 LAB10 50.000 Label Apple Blossom 100ml

AB250 BS01 12.000 Base Shampoo

AB250 BT250 48.000 Bottle 250ml

AB250 CAPF 48.000 Flip cap

AB250 CARL 1.000 Carton large



AB500 BS01 12.000 Base ShampooAB500 BT500 24.000 Bottle 500ml

AB500 CAPS 24.000 Screw cap

AB500 CARL 1.000 Carton large



FL100 BS01 4.800 Base Shampoo

FL100 BT100 48.000 Bottle 100ml

FL100 CAPF 48.000 Flip cap

FL100 CARS 1.000 Carton small

FL100 ESL 0.048 Lemon essence

FL100 LFL10 50.000 Label Fragrant Lemon 100ml

FL250 BS01 12.000 Base ShampooFL250 BT250 48.000 Bottle 250ml

FL250 CAPF 48.000 Flip cap

FL250 CARL 1.000 Carton large



FL500 BS01 12.000 Base Shampoo

FL500 BT500 24.000 Bottle 500ml

FL500 CAPS 24.000 Screw cap

FL500 CARL 1.000 Carton large



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Purchase Orders

This table lists the components that are on order from the suppliers, and the date they are due to

be delivered.

Code Description Supplier Supplier Name Qty Due in

BS01 Base Shampoo AC01 Ace Chemicals 100,000 18-Mar-00BS01 Base Shampoo AC01 Ace Chemicals 100,000 30-Mar-00

BT100 Bottle 100ml BP01 Best Plastics 40,000 14-Apr-00

BT250 Bottle 250ml BP01 Best Plastics 90,000 18-Mar-00



BT500 Bottle 500ml BP01 Best Plastics 100,000 16-Mar-00



CAPF Flip cap BP01 Best Plastics 200,000 16-Mar-00

CAPF Flip cap BP01 Best Plastics 300,000 7-Apr-00

CAPS Screw cap BP01 Best Plastics 100,000 17-Mar-00

CAPS Screw cap BP01 Best Plastics 100,000 2-Apr-00CARL Carton large EC01 Eduardo Corrugates 8,000 14-Mar-00

CARL Carton large EC01 Eduardo Corrugates 5,000 4-Apr-00

CARS Carton small EC01 Eduardo Corrugates 1,000 18-Mar-00

CARS Carton small EC01 Eduardo Corrugates 1,000 26-Apr-00

ESA Apple essence CE01 Chang Essences 60 23-Mar-00

ESA Apple essence CE01 Chang Essences 100 6-Apr-00

ESL Lemon essence CE01 Chang Essences 350 3-Apr-00

LAB10 Label Apple Blossom 100ml DP01 Dave's Printing 50,000 7-Apr-00

LAB25 Label Apple Blossom 250ml DP01 Dave's Printing 70,000 14-Mar-00

LAB25 Label Apple Blossom 250ml DP01 Dave's Printing 60,000 21-Mar-00

LAB50 Label Apple Blossom 500ml DP01 Dave's Printing 20,000 2-Apr-00

LAB50 Label Apple Blossom 500ml DP01 Dave's Printing 20,000 16-Apr-00LAB50 Label Apple Blossom 500ml DP01 Dave's Printing 20,000 30-Apr-00

LFL10 Label Fragrant Lemon 100ml DP01 Dave's Printing 10,000 14-Apr-00


LFL25 Label Fragrant Lemon 250ml DP01 Dave's Printing 60,000 17-Mar-00




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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

Start of the first job: 14/3 8:00 AB100 AB250 AB500 FL100 FL250 FL500 AB100 AB250 AB

Product running now: AB500 Speed - cartons per hour 88 88 175 88 88 175

Quantity committed: 110 Forecast sales - cartons per week 1,000 1,400 800 200 1,200 1,600Min cover - weeks 0.5 0.5 0.5 0.5 0.5 0.5

Utilization: 35.48% Max cover - weeks 2.0 2.0 2.0 2.0 2.0 2.0

Min cover - cartons 500 700 400 100 600 800

Max cover - cartons 2,000 2,800 1,600 400 2,400 3,200

Product Force Qty Force Force Start Stop Projected Inventory - units Projecte

Opening stock: 14/3 8:00 1,854 1,470 470 488 1,148 766 1.85 1.05

AB500 110 0.0 0.6 14/3 8:00 14/3 8:37 1,850 1,465 577 487 1,144 760 1.85 1.05

FL500 2,580 0.0 14.7 14/3 8:37 14/3 23:22 1,763 1,342 507 470 1,038 3,200 1.76 0.96

Idle 0 22.4 0.0 14/3 23:22 15/3 21:48 1,629 1,155 400 443 878 2,986 1.63 0.83

AB500 1,234 0.0 7.1 15/3 21:48 16/3 4:51 1,587 1,096 1,600 435 828 2,919 1.59 0.78

Idle 0 31.9 0.0 16/3 4:51 17/3 12:43 1,397 831 1,449 397 600 2,615 1.40 0.59

FL250 1,960 0.0 22.4 17/3 12:43 18/3 11:07 1,264 644 1,342 370 2,400 2,402 1.26 0.46

AB250 2,383 0.0 27.2 18/3 11:07 19/3 14:21 1,102 2,800 1,212 338 2,205 2,143 1.10 2.00

Idle 0 101.1 0.0 19/3 14:21 23/3 19:28 500 1,957 731 217 1,483 1,180 0.50 1.40

AB100 1,609 0.0 18.4 23/3 19:28 24/3 13:51 2,000 1,804 643 195 1,352 1,004 2.00 1.29

Idle 0 21.5 0.0 24/3 13:51 25/3 11:19 1,872 1,625 541 170 1,198 800 1.87 1.16

FL500 2,538 0.0 14.5 25/3 11:19 26/3 1:49 1,785 1,504 472 152 1,095 3,200 1.79 1.07

Idle 0 15.1 0.0 26/3 1:49 26/3 16:56 1,696 1,379 400 135 987 3,056 1.70 0.98

AB500 1,234 0.0 7.1 26/3 16:56 26/3 23:59 1,654 1,320 1,600 126 937 2,989 1.65 0.94

Idle 0 21.9 0.0 26/3 23:59 27/3 21:55 1,523 1,137 1,496 100 780 2,780 1.52 0.81

FL100 304 0.0 3.5 27/3 21:55 28/3 1:23 1,502 1,108 1,479 400 755 2,747 1.50 0.79

Idle 0 21.7 0.0 28/3 1:23 28/3 23:07 1,373 927 1,376 374 600 2,540 1.37 0.66

FL250 1,960 0.0 22.4 28/3 23:07 29/3 21:31 1,240 740 1,269 347 2,400 2,327 1.24 0.53

Idle 0 4.8 0.0 29/3 21:31 30/3 2:21 1,211 700 1,246 342 2,365 2,281 1.21 0.50

AB250 2,321 0.0 26.5 30/3 2:21 31/3 4:53 1,053 2,800 1,120 310 2,176 2,028 1.05 2.00

Idle 0 92.9 0.0 31/3 4:53 4/4 1:47 500 2,026 678 199 1,512 1,143 0.50 1.45

AB100 1,609 0.0 18.4 4/4 1:47 4/4 20:10 2,000 1,873 590 178 1,381 968 2.00 1.34

Idle 0 17.6 0.0 4/4 20:10 5/4 13:49 1,894 1,725 506 156 1,255 800 1.89 1.23

FL500 2,538 0.0 14.5 5/4 13:49 6/4 4:19 1,808 1,605 437 139 1,151 3,200 1.81 1.15Idle 0 7.8 0.0 6/4 4:19 6/4 12:04 1,762 1,540 400 130 1,096 3,126 1.76 1.10

www.production-scheduling.com

Idlehours

Runhours

12-Mar 15-Mar 18-Mar 21-Mar 24-Mar 27-Mar 30-Mar 2-Apr 5-A

0.3

0.5

0.8

1.0

1.3

1.5

1.8

2.0

2.3

2.5

Projected InventoryCover

W e e k s



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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

-

-

- 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 duration of the next job is calculated, and the cycle begins again

-

-

the opening inventory is recorded at the top of the columns, and would typically come from an inventorymanagement 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

the quantity to make is that required to increase the inventory level to the maximum, plus sufficient toreplenish the amount sold while the job was running

if the projected inventory level of the lowest cover product is above its minimum, then an idle period isscheduled

the duration of the idle period is the time it will take for forecast sales to reduce the inventory to theminimum and trigger the next run

You will see from the chart of inventory cover, that the model attempts to keep the inventory of each productbetween the minimum and maximum.

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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.

Sum - Qty

Prod/Run Prod Product Start Run

AB100 23/3 19:28 1609

/1 ### 1609 1AB250 18/3 11:07 2383

30/3 2:21 2321

AB500 14/3 8:00 110

15/3 21:48 1234

26/3 16:56 1234

FL100 27/3 21:55 304

FL250 17/3 12:43 1960

28/3 23:07 1960

FL500 14/3 8:37 2580

25/3 11:19 2538

/1 ### 2538 1

Total Result 22380

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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.

Component Start Date

AB100/1 BS01 4.8 #N/A 30-Dec-99 0 0AB100/1 BT100 48 #N/A 30-Dec-99 0 0

AB100/1 CAPF 48 #N/A 30-Dec-99 0 0

AB100/1 CARS 1 #N/A 30-Dec-99 0 0

AB100/1 ESA 0.05 #N/A 30-Dec-99 0 0

AB100/1 LAB10 50 #N/A 30-Dec-99 0 0

AB250/1 BS01 12 #N/A 30-Dec-99 0 0

AB250/1 BT250 48 #N/A 30-Dec-99 0 0

AB250/1 CAPF 48 #N/A 30-Dec-99 0 0

AB250/1 CARL 1 #N/A 30-Dec-99 0 0

AB250/1 ESA 0.12 #N/A 30-Dec-99 0 0

AB250/1 LAB25 50 #N/A 30-Dec-99 0 0

AB500/1 BS01 12 #N/A 30-Dec-99 0 0AB500/1 BT500 24 #N/A 30-Dec-99 0 0

AB500/1 CAPS 24 #N/A 30-Dec-99 0 0

AB500/1 CARL 1 #N/A 30-Dec-99 0 0

AB500/1 ESA 0.12 #N/A 30-Dec-99 0 0

AB500/1 LAB50 26 #N/A 30-Dec-99 0 0

FL100/1 BS01 4.8 #N/A 30-Dec-99 0 0

FL100/1 BT100 48 #N/A 30-Dec-99 0 0

FL100/1 CAPF 48 #N/A 30-Dec-99 0 0

FL100/1 CARS 1 #N/A 30-Dec-99 0 0

FL100/1 ESL 0.05 #N/A 30-Dec-99 0 0

FL100/1 LFL10 50 #N/A 30-Dec-99 0 0

FL250/1 BS01 12 #N/A 30-Dec-99 0 0FL250/1 BT250 48 #N/A 30-Dec-99 0 0

FL250/1 CAPF 48 #N/A 30-Dec-99 0 0

FL250/1 CARL 1 #N/A 30-Dec-99 0 0

FL250/1 ESL 0.12 #N/A 30-Dec-99 0 0

FL250/1 LFL25 50 #N/A 30-Dec-99 0 0

FL500/1 BS01 12 #N/A 30-Dec-99 0 0

FL500/1 BT500 24 #N/A 30-Dec-99 0 0

FL500/1 CAPS 24 #N/A 30-Dec-99 0 0

FL500/1 CARL 1 #N/A 30-Dec-99 0 0

FL500/1 ESL 0.12 #N/A 30-Dec-99 0 0

FL500/1 LFL50 26 #N/A 30-Dec-99 0 0

/1 0 0 7 4-Apr-09 1609 0/1 0 0 7 4-Apr-09 1609 0

/1 0 0 7 4-Apr-09 1609 0

/1 0 0 7 4-Apr-09 1609 0

/1 0 0 7 4-Apr-09 1609 0

/1 0 0 7 4-Apr-09 1609 0

/1 0 0 7 4-Apr-09 1609 0

/1 0 0 7 4-Apr-09 1609 0

/1 0 0 7 4-Apr-09 1609 0

/1 0 0 7 4-Apr-09 1609 0

AB100/2 BS01 4.8 #N/A 30-Dec-99 0 0

AB100/2 BT100 48 #N/A 30-Dec-99 0 0

AB100/2 CAPF 48 #N/A 30-Dec-99 0 0AB100/2 CARS 1 #N/A 30-Dec-99 0 0

Product/Run

Qtyeach

ProductionRun Index

ProductionQty

ComponentQuantityRequired

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AB100/2 ESA 0.05 #N/A 30-Dec-99 0 0

AB100/2 LAB10 50 #N/A 30-Dec-99 0 0

AB250/2 BS01 12 #N/A 30-Dec-99 0 0

AB250/2 BT250 48 #N/A 30-Dec-99 0 0

AB250/2 CAPF 48 #N/A 30-Dec-99 0 0

AB250/2 CARL 1 #N/A 30-Dec-99 0 0

AB250/2 ESA 0.12 #N/A 30-Dec-99 0 0AB250/2 LAB25 50 #N/A 30-Dec-99 0 0

AB500/2 BS01 12 #N/A 30-Dec-99 0 0

AB500/2 BT500 24 #N/A 30-Dec-99 0 0

AB500/2 CAPS 24 #N/A 30-Dec-99 0 0

AB500/2 CARL 1 #N/A 30-Dec-99 0 0

AB500/2 ESA 0.12 #N/A 30-Dec-99 0 0

AB500/2 LAB50 26 #N/A 30-Dec-99 0 0

FL100/2 BS01 4.8 #N/A 30-Dec-99 0 0

FL100/2 BT100 48 #N/A 30-Dec-99 0 0

FL100/2 CAPF 48 #N/A 30-Dec-99 0 0

FL100/2 CARS 1 #N/A 30-Dec-99 0 0

FL100/2 ESL 0.05 #N/A 30-Dec-99 0 0FL100/2 LFL10 50 #N/A 30-Dec-99 0 0

FL250/2 BS01 12 #N/A 30-Dec-99 0 0

FL250/2 BT250 48 #N/A 30-Dec-99 0 0

FL250/2 CAPF 48 #N/A 30-Dec-99 0 0

FL250/2 CARL 1 #N/A 30-Dec-99 0 0

FL250/2 ESL 0.12 #N/A 30-Dec-99 0 0

FL250/2 LFL25 50 #N/A 30-Dec-99 0 0

FL500/2 BS01 12 #N/A 30-Dec-99 0 0

FL500/2 BT500 24 #N/A 30-Dec-99 0 0

FL500/2 CAPS 24 #N/A 30-Dec-99 0 0

FL500/2 CARL 1 #N/A 30-Dec-99 0 0

FL500/2 ESL 0.12 #N/A 30-Dec-99 0 0FL500/2 LFL50 26 #N/A 30-Dec-99 0 0

/2 0 0 #N/A 30-Dec-99 0 0

/2 0 0 #N/A 30-Dec-99 0 0

/2 0 0 #N/A 30-Dec-99 0 0

/2 0 0 #N/A 30-Dec-99 0 0

/2 0 0 #N/A 30-Dec-99 0 0

/2 0 0 #N/A 30-Dec-99 0 0

/2 0 0 #N/A 30-Dec-99 0 0

/2 0 0 #N/A 30-Dec-99 0 0

/2 0 0 #N/A 30-Dec-99 0 0

/2 0 0 #N/A 30-Dec-99 0 0

AB100/3 BS01 4.8 #N/A 30-Dec-99 0 0AB100/3 BT100 48 #N/A 30-Dec-99 0 0

AB100/3 CAPF 48 #N/A 30-Dec-99 0 0

AB100/3 CARS 1 #N/A 30-Dec-99 0 0

AB100/3 ESA 0.05 #N/A 30-Dec-99 0 0

AB100/3 LAB10 50 #N/A 30-Dec-99 0 0

AB250/3 BS01 12 #N/A 30-Dec-99 0 0

AB250/3 BT250 48 #N/A 30-Dec-99 0 0

AB250/3 CAPF 48 #N/A 30-Dec-99 0 0

AB250/3 CARL 1 #N/A 30-Dec-99 0 0

AB250/3 ESA 0.12 #N/A 30-Dec-99 0 0

AB250/3 LAB25 50 #N/A 30-Dec-99 0 0

AB500/3 BS01 12 #N/A 30-Dec-99 0 0AB500/3 BT500 24 #N/A 30-Dec-99 0 0

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AB500/3 CAPS 24 #N/A 30-Dec-99 0 0

AB500/3 CARL 1 #N/A 30-Dec-99 0 0

AB500/3 ESA 0.12 #N/A 30-Dec-99 0 0

AB500/3 LAB50 26 #N/A 30-Dec-99 0 0

FL100/3 BS01 4.8 #N/A 30-Dec-99 0 0

FL100/3 BT100 48 #N/A 30-Dec-99 0 0

FL100/3 CAPF 48 #N/A 30-Dec-99 0 0FL100/3 CARS 1 #N/A 30-Dec-99 0 0

FL100/3 ESL 0.05 #N/A 30-Dec-99 0 0

FL100/3 LFL10 50 #N/A 30-Dec-99 0 0

FL250/3 BS01 12 #N/A 30-Dec-99 0 0

FL250/3 BT250 48 #N/A 30-Dec-99 0 0

FL250/3 CAPF 48 #N/A 30-Dec-99 0 0

FL250/3 CARL 1 #N/A 30-Dec-99 0 0

FL250/3 ESL 0.12 #N/A 30-Dec-99 0 0

FL250/3 LFL25 50 #N/A 30-Dec-99 0 0

FL500/3 BS01 12 #N/A 30-Dec-99 0 0

FL500/3 BT500 24 #N/A 30-Dec-99 0 0

FL500/3 CAPS 24 #N/A 30-Dec-99 0 0FL500/3 CARL 1 #N/A 30-Dec-99 0 0

FL500/3 ESL 0.12 #N/A 30-Dec-99 0 0

FL500/3 LFL50 26 #N/A 30-Dec-99 0 0

/3 0 0 #N/A 30-Dec-99 0 0

/3 0 0 #N/A 30-Dec-99 0 0

/3 0 0 #N/A 30-Dec-99 0 0

/3 0 0 #N/A 30-Dec-99 0 0

/3 0 0 #N/A 30-Dec-99 0 0

/3 0 0 #N/A 30-Dec-99 0 0

/3 0 0 #N/A 30-Dec-99 0 0

/3 0 0 #N/A 30-Dec-99 0 0

/3 0 0 #N/A 30-Dec-99 0 0/3 0 0 #N/A 30-Dec-99 0 0

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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 - Component Quantity Required

ComponenStart Date Product/Run Compone Start Date DescriptionBS01 12/30/99 AB100/1 0 #N/A #N/A

AB100/2 0 #N/A #N/A

AB100/3 0 #N/A #N/A

AB250/1 0 #N/A #N/A

AB250/2 0 #N/A #N/A

AB250/3 0 #N/A #N/A

AB500/1 0 #N/A #N/A

AB500/2 0 #N/A #N/A

AB500/3 0 #N/A #N/A

FL100/1 0 #N/A #N/A

FL100/2 0 #N/A #N/A

FL100/3 0 #N/A #N/AFL250/1 0 #N/A #N/A

FL250/2 0 #N/A #N/A

FL250/3 0 #N/A #N/A

FL500/1 0 #N/A #N/A

FL500/2 0 #N/A #N/A

FL500/3 0 #N/A #N/A

BT100 12/30/99 AB100/1 0 #N/A #N/A

AB100/2 0 #N/A #N/A

AB100/3 0 #N/A #N/A

FL100/1 0 #N/A #N/A

FL100/2 0 #N/A #N/A

FL100/3 0 #N/A #N/ABT250 12/30/99 AB250/1 0 #N/A #N/A

AB250/2 0 #N/A #N/A

AB250/3 0 #N/A #N/A

FL250/1 0 #N/A #N/A

FL250/2 0 #N/A #N/A

FL250/3 0 #N/A #N/A

BT500 12/30/99 AB500/1 0 #N/A #N/A

AB500/2 0 #N/A #N/A

AB500/3 0 #N/A #N/A

FL500/1 0 #N/A #N/A

FL500/2 0 #N/A #N/A

FL500/3 0 #N/A #N/ACAPF 12/30/99 AB100/1 0 #N/A #N/A

AB100/2 0 #N/A #N/A

AB100/3 0 #N/A #N/A

AB250/1 0 #N/A #N/A

AB250/2 0 #N/A #N/A

AB250/3 0 #N/A #N/A

FL100/1 0 #N/A #N/A

FL100/2 0 #N/A #N/A

FL100/3 0 #N/A #N/A

FL250/1 0 #N/A #N/A

FL250/2 0 #N/A #N/A

FL250/3 0 #N/A #N/ACAPS 12/30/99 AB500/1 0 #N/A #N/A

Item

Index

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AB500/2 0 #N/A #N/A

AB500/3 0 #N/A #N/A

FL500/1 0 #N/A #N/A

FL500/2 0 #N/A #N/A

FL500/3 0 #N/A #N/A

CARL 12/30/99 AB250/1 0 #N/A #N/A

AB250/2 0 #N/A #N/AAB250/3 0 #N/A #N/A

AB500/1 0 #N/A #N/A

AB500/2 0 #N/A #N/A

AB500/3 0 #N/A #N/A

FL250/1 0 #N/A #N/A

FL250/2 0 #N/A #N/A

FL250/3 0 #N/A #N/A

FL500/1 0 #N/A #N/A

FL500/2 0 #N/A #N/A

FL500/3 0 #N/A #N/A

CARS 12/30/99 AB100/1 0 #N/A #N/A

AB100/2 0 #N/A #N/AAB100/3 0 #N/A #N/A

FL100/1 0 #N/A #N/A

FL100/2 0 #N/A #N/A

FL100/3 0 #N/A #N/A

ESA 12/30/99 AB100/1 0 #N/A #N/A

AB100/2 0 #N/A #N/A

AB100/3 0 #N/A #N/A

AB250/1 0 #N/A #N/A

AB250/2 0 #N/A #N/A

AB250/3 0 #N/A #N/A

AB500/1 0 #N/A #N/A

AB500/2 0 #N/A #N/AAB500/3 0 #N/A #N/A

ESL 12/30/99 FL100/1 0 #N/A #N/A

FL100/2 0 #N/A #N/A

FL100/3 0 #N/A #N/A

FL250/1 0 #N/A #N/A

FL250/2 0 #N/A #N/A

FL250/3 0 #N/A #N/A

FL500/1 0 #N/A #N/A

FL500/2 0 #N/A #N/A

FL500/3 0 #N/A #N/A

LAB10 12/30/99 AB100/1 0 #N/A #N/A

AB100/2 0 #N/A #N/AAB100/3 0 #N/A #N/A

LAB25 12/30/99 AB250/1 0 #N/A #N/A

AB250/2 0 #N/A #N/A

AB250/3 0 #N/A #N/A

LAB50 12/30/99 AB500/1 0 #N/A #N/A

AB500/2 0 #N/A #N/A

AB500/3 0 #N/A #N/A

LFL10 12/30/99 FL100/1 0 #N/A #N/A

FL100/2 0 #N/A #N/A

FL100/3 0 #N/A #N/A

LFL25 12/30/99 FL250/1 0 #N/A #N/A

FL250/2 0 #N/A #N/AFL250/3 0 #N/A #N/A

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LFL50 12/30/99 FL500/1 0 #N/A #N/A

FL500/2 0 #N/A #N/A

FL500/3 0 #N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A

#N/A #N/A#N/A #N/A

#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 18-Mar-00 Base Shampoo

BS01 30-Mar-00 Base Shampoo

BT100 14-Apr-00 Bottle 100ml

BT250 18-Mar-00 Bottle 250ml

BT250 1-Apr-00 Bottle 250mlBT250 22-Apr-00 Bottle 250ml

BT500 16-Mar-00 Bottle 500ml



CAPF 16-Mar-00 Flip cap

CAPF 7-Apr-00 Flip cap

CAPS 17-Mar-00 Screw cap

CAPS 2-Apr-00 Screw cap

CARL 14-Mar-00 Carton large

CARL 4-Apr-00 Carton large

CARS 18-Mar-00 Carton small

CARS 26-Apr-00 Carton smallESA 23-Mar-00 Apple essence

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ESA 6-Apr-00 Apple essence

ESL 3-Apr-00 Lemon essence

LAB10 7-Apr-00 Label Apple Blossom 1

LAB25 14-Mar-00 Label Apple Blossom 2

LAB25 21-Mar-00 Label Apple Blossom 2

LAB50 2-Apr-00 Label Apple Blossom 5

LAB50 16-Apr-00 Label Apple Blossom 5LAB50 30-Apr-00 Label Apple Blossom 5

LFL10 14-Apr-00 Label Fragrant Lemon 1

LFL10 28-Apr-00 Label Fragrant Lemon 1

LFL25 17-Mar-00 Label Fragrant Lemon



LFL50 13-Apr-00 Label Fragrant Lemon

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5 6 8

Supplier Supplier Name Inventory Get In On order #N/A #N/A #N/A #N/A #N/A

#N/A #N/A #N/A #N/A #N/A










#N/A #N/A #N/A #N/A #N/A#N/A #N/A #N/A #N/A #N/A


































Balance

Remaining

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AC01 Ace Chemicals 100,000

AC01 Ace Chemicals 100,000

BP01 Best Plastics 40,000


BP01 Best Plastics 40,000BP01 Best Plastics 50,000








EC01 Eduardo Corrugates 8,000



EC01 Eduardo Corrugates 1,000CE01 Chang Essences 60

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CE01 Chang Essences 100

CE01 Chang Essences 350

DP01 Dave's Printing 50,000




DP01 Dave's Printing 20,000DP01 Dave's Printing 20,000







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http://www.production-scheduling.com Page 25 of 40

Components that will be required after inventory has been exhausted are listed here

and compared with components on order.

Columns A to F are a PivotTable of the Allocate Inventory worksheet, and G contains

a formula to calculate projected inventory of each component. Negative projected

inventory indicates that orders need to be chased or placed to support scheduled

production.

Get In - all -

Data

Supplier Name Description Start Date Product/Run Sum - Get ISum - On Total Sum Total Sum

#N/A #N/A (empty) (empty) #VALUE! #VALUE!

AB100/1 #VALUE! #VALUE!





AB250/3 #VALUE! #VALUE!AB500/1 #VALUE! #VALUE!



FL100/1 #VALUE! #VALUE!









#N/A Result #VALUE! #VALUE!

(empty) (empty) (empty) (empty)

Result

Ace Chemicals Base Sham 03/18/00 (empty) 100000 100000

03/30/00 (empty) 100000 100000

Base Shampoo Result 200000 200000

Best Plastics Bottle 100ml04/14/00 (empty) 40000 40000

Bottle 100ml Result 40000 40000

Bottle 250ml03/18/00 (empty) 90000 90000

04/01/00 (empty) 40000 40000

04/22/00 (empty) 50000 50000


Bottle 500ml03/16/00 (empty) 100000 10000004/01/00 (empty) 50000 50000

04/15/00 (empty) 50000 50000


Flip cap 03/16/00 (empty) 200000 200000

04/07/00 (empty) 300000 300000

Flip cap Result 500000 500000

Screw cap 03/17/00 (empty) 100000 100000

04/02/00 (empty) 100000 100000

Screw cap Result 200000 200000

Chang EssenceApple essen03/23/00 (empty) 60 60

04/06/00 (empty) 100 100

Apple essence Result 160 160Lemon esse04/03/00 (empty) 350 350

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Lemon essence Result 350 350

Dave's Printing Label Apple 04/07/00 (empty) 50000 50000

Label Apple Blossom 100ml Result 50000 50000

Label Apple 03/14/00 (empty) 70000 70000

03/21/00 (empty) 60000 60000

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Label Apple 04/02/00 (empty) 20000 20000

04/16/00 (empty) 20000 20000

04/30/00 (empty) 20000 20000


Label Fragr 04/14/00 (empty) 10000 10000

04/28/00 (empty) 10000 10000Label Fragrant Lemon 100ml Result 20000 20000


03/31/00 (empty) 60000 60000

Label Fragrant Lemon 250ml Result 120000 120000


04/13/00 (empty) 40000 40000

Label Fragrant Lemon 500ml Result 80000 80000

Eduardo CorrugCarton large03/14/00 (empty) 8000 8000

04/04/00 (empty) 5000 5000

Carton large Result 13000 13000

Carton smal03/18/00 (empty) 1000 1000

04/26/00 (empty) 1000 1000Carton small Result 2000 2000

0

0

0

0

0

0

0

0

0

0

0

00

0

0

0

0

0

0

0

0

0

0

00

0

0

0

0

0

0

0

0

0

0

00

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0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

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- On order

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Inventory Rationing Logic

Inventory rationing addresses a question that many manufacturers have:

"What products should I make with the inventory I have on hand right now?"

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 calculation involves circular, iterative references as follows:

Formula link:

PivotTable link:

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

The system takes into account raw materials that are used by more than one product, and rations theinventory across the products so as to even out the product inventory cover as much as possible.

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 thathas not yet been used. The forecast usage of each component is then calculated from the sales forecastof the products they are used on, times the quantity used in each case of product. From this, theaverage cover of each component is calculated.

Finished products which have a cover above the average, then have their components and their forecasteliminated from the calculation, and the average is re-calculated. The quantity of each product that canbe 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, andthe Second Pass Calculations repeat the logic again to determinte what products could be made with thecomponents that are left over.

InventoryRationing

Calculation

ComponentsPivot

Products Pivot

F

F

P

P

F

P

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8 8

Bill of Materials First Pass Calc

Product Component Qty Component Description

AB100 BS01 4.800 Base Shampoo 1000 1854 1.85 #N/A #N/A 34276 #N/A #VA

AB100 BT100 48.000 Bottle 100ml 1000 1854 1.85 #N/A #N/A 122472 #N/A #VA

AB100 CAPF 48.000 Flip cap 1000 1854 1.85 #N/A #N/A 65738 #N/A #VA

AB100 CARS 1.000 Carton small 1000 1854 1.85 #N/A #N/A 998 #N/A #VA

AB100 ESA 0.048 Apple essence 1000 1854 1.85 #N/A #N/A 1494 #N/A #VA

AB100 LAB10 50.000 Label Apple Blossom 100ml 1000 1854 1.85 #N/A #N/A 211796 #N/A #VA



AB250 CAPF 48.000 Flip cap 1400 1470 1.05 #N/A #N/A 65738 #N/A #VA

AB250 CARL 1.000 Carton large 1400 1470 1.05 #N/A #N/A 4368 #N/A #VA

AB250 ESA 0.120 Apple essence 1400 1470 1.05 #N/A #N/A 1494 #N/A #VA




AB500 CAPS 24.000 Screw cap 800 470 0.59 #N/A #N/A 37818 #N/A #VA

AB500 CARL 1.000 Carton large 800 470 0.59 #N/A #N/A 4368 #N/A #VAAB500 ESA 0.120 Apple essence 800 470 0.59 #N/A #N/A 1494 #N/A #VA


FL100 BS01 4.800 Base Shampoo 200 488 2.44 #N/A #N/A 34276 #N/A #VA

FL100 BT100 48.000 Bottle 100ml 200 488 2.44 #N/A #N/A 122472 #N/A #VA

FL100 CAPF 48.000 Flip cap 200 488 2.44 #N/A #N/A 65738 #N/A #VA

FL100 CARS 1.000 Carton small 200 488 2.44 #N/A #N/A 998 #N/A #VA

FL100 ESL 0.048 Lemon essence 200 488 2.44 #N/A #N/A 1002 #N/A #VA

FL100 LFL10 50.000 Label Fragrant Lemon 100ml 200 488 2.44 #N/A #N/A 32140 #N/A #VA

FL250 BS01 12.000 Base Shampoo 1200 1148 0.96 #N/A #N/A 34276 #N/A #VA

FL250 BT250 48.000 Bottle 250ml 1200 1148 0.96 #N/A #N/A 184968 #N/A #VA

FL250 CAPF 48.000 Flip cap 1200 1148 0.96 #N/A #N/A 65738 #N/A #VA

FL250 CARL 1.000 Carton large 1200 1148 0.96 #N/A #N/A 4368 #N/A #VA



FL500 BS01 12.000 Base Shampoo 1600 766 0.48 #N/A #N/A 34276 #N/A #VAFL500 BT500 24.000 Bottle 500ml 1600 766 0.48 #N/A #N/A 36516 #N/A #VA

FL500 CAPS 24.000 Screw cap 1600 766 0.48 #N/A #N/A 37818 #N/A #VA

FL500 CARL 1.000 Carton large 1600 766 0.48 #N/A #N/A 4368 #N/A #VA



ProductSales

Forcastper Week

ProductInventory

ProductInventory

Cover Weeks

ComponentSales Forcast

per Week

TotalComponent

SalesForecast

Componentsin Inventory

Componentsin ProductInventory

CominIn

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Second Pass Calculations

#N/A #N/A 28714 #N/A #N/A #N/A 4800 5562 #N/A 2342.4 1.65 #N/A #N/A #N

#N/A #N/A 0 #N/A #N/A #N/A 48000 122472 #N/A 23424 3.04 #N/A #N/A #N














#N/A #N/A 2393 #N/A #N/A #N/A 800 1975 #N/A 0 2.47 #N/A #N/A #N#N/A #N/A 103 #N/A #N/A #N/A 96 1391 #N/A 0 14.49 #N/A #N/A #N






#N/A #N/A 184 #N/A #N/A #N/A 9.6 818 #N/A 23.42 87.63 #N/A #N/A #N








#N/A #N/A 28714 #N/A #N/A #N/A 19200 5562 #N/A 2342.4 0.41 #N/A #N/A #N#N/A #N/A 36516 #N/A #N/A #N/A 38400 0 #N/A 0 0.00 #N/A #N/A #N





MakeProduct

UseComponent

Total UseComponent

ProductInventory

2

ProductInventory

Cover Weeks 2

ComponentSales

Forcast per Week 2

TotalComponent Sales

Forecast 2

Components in

Inventory2

Components in

ProductInventory

2

TotalCompone

nts inProduct

Inventory2

TotalAverageInventoryCover 2

ProductCover Below

Average 2

MinAverageCover 2

MakeWeeks

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#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A

#N/A#N/A

#N/A

#N/A

#N/A

#N/A

MakeProduct

1+2

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Data

Component Sum - Compon Sum - CompoSum - Use Co Sum - ComponSum - CompoSum - Use Co

BS01 #VALUE! #VALUE! 28714.48 960 2342.4 2391.21

BT100 #VALUE! #VALUE! 0 9600 23424 23912.08

BT250 #VALUE! #VALUE! 41825.92 0 0 0

BT500 #VALUE! #VALUE! 36516 0 0 0

CAPF #VALUE! #VALUE! 41825.92 9600 23424 23912.08

CAPS #VALUE! #VALUE! 36516 0 0 0

CARL #VALUE! #VALUE! 2392.87 0 0 0

CARS #VALUE! #VALUE! 0 200 488 498.17

ESA #VALUE! #VALUE! 102.97 0 0 0

ESL #VALUE! #VALUE! 184.18 9.6 23.42 23.91LAB10 #VALUE! #VALUE! 0 0 0 0

LAB25 #VALUE! #VALUE! 20444.67 0 0 0

LAB50 #VALUE! #VALUE! 11678.33 0 0 0

LFL10 #VALUE! #VALUE! 0 10000 24400 24908.42

LFL25 #VALUE! #VALUE! 23124 0 0 0

LFL50 #VALUE! #VALUE! 27880.67 0 0 0

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Total Sum Total Sum Total Sum Total Sum Total Sum Total Sum - Use Component 2

#VALUE! #VALUE! 28714.48 960 2342.4 2391.21

#VALUE! #VALUE! 0 9600 23424 23912.08

#VALUE! #VALUE! 41825.92 0 0 0

#VALUE! #VALUE! 36516 0 0 0

#VALUE! #VALUE! 41825.92 9600 23424 23912.08

#VALUE! #VALUE! 36516 0 0 0

#VALUE! #VALUE! 2392.87 0 0 0

#VALUE! #VALUE! 0 200 488 498.17

#VALUE! #VALUE! 102.97 0 0 0

#VALUE! #VALUE! 184.18 9.6 23.42 23.91#VALUE! #VALUE! 0 0 0 0

#VALUE! #VALUE! 20444.67 0 0 0

#VALUE! #VALUE! 11678.33 0 0 0

#VALUE! #VALUE! 0 10000 24400 24908.42

#VALUE! #VALUE! 23124 0 0 0

#VALUE! #VALUE! 27880.67 0 0 0

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Data

Product Min - Total Av Min - Total Av Sum - Make P Total Min Total Min Total Sum - Make Pr

AB100 #VALUE! 0.99 #VALUE! #VALUE! 0.99 #VALUE!



FL100 #VALUE! 4.93 #VALUE! #VALUE! 4.93 #VALUE!



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duct 1+2

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mrp_excel_896