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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

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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.

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.
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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.

Inventory Rationing Calculations

Purchase Action Report
Links to :

Components Pivot
Allocate Inventory
Purchase Orders

Production Runs
Supplier Master

Finite Schedule

Products Pivot
Bill of Material
The Business
Item Master

BOM x 3
Worksheet
The Business
Item 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:
P F P P Purchase
Finite Production Allocate Action
BOM x 3
Schedule Runs Inventory Report

Purchase F
Orders

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
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to be refreshed.

n the workbook.
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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 Description Bottles per Carton Forecast Cartons per Week

AB100 Apple Blossom 100ml 48 1000
AB250 Apple Blossom 250ml 48 1400
AB500 Apple Blossom 500ml 24 800
FL100 Fragrant Lemon 100ml 48 200
FL250 Fragrant Lemon 250ml 48 1200
FL500 Fragrant Lemon 500ml 24 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.
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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 MS Query.

Unit of
Code Description Measure Warehouse Supplier Supplier Name
AB100 Apple Blossom 100ml carton FP 01 #N/A
AB250 Apple Blossom 250ml carton FP 01 #N/A
AB500 Apple Blossom 500ml carton FP 01 #N/A
FL100 Fragrant Lemon 100ml carton FP 01 #N/A
FL250 Fragrant Lemon 250ml carton FP 01 #N/A
FL500 Fragrant Lemon 500ml 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 Plastics
BT500 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
LAB25 Label Apple Blossom 250ml each RM DP01 Dave's Printing
LAB50 Label Apple Blossom 500ml each RM DP01 Dave's Printing
LFL10 Label Fragrant Lemon 100ml each RM DP01 Dave's Printing
LFL25 Label Fragrant Lemon 250ml each RM DP01 Dave's Printing
LFL50 Label Fragrant Lemon 500ml each RM DP01 Dave's Printing
CARS Carton small each RM EC01 Eduardo Corrugates
CARL Carton large each RM EC01 Eduardo Corrugates
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link and MS Query.

Lead
Time
Days Inventory
1,854
1,470
470
488
1,148
766
14 34,276
30 1,494
30 1,002
21 122,472
21 184,968
21 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
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Supplier Master

Code Supplier Name

AC01 Ace Chemicals
BP01 Best Plastics
CE01 Chang Essences
DP01 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
AB250 ESA 0.120 Apple essence
AB250 LAB25 50.000 Label Apple Blossom 250ml
AB500 BS01 12.000 Base Shampoo
AB500 BT500 24.000 Bottle 500ml
AB500 CAPS 24.000 Screw cap
AB500 CARL 1.000 Carton large
AB500 ESA 0.120 Apple essence
AB500 LAB50 26.000 Label Apple Blossom 500ml
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 Shampoo
FL250 BT250 48.000 Bottle 250ml
FL250 CAPF 48.000 Flip cap
FL250 CARL 1.000 Carton large
FL250 ESL 0.120 Lemon essence
FL250 LFL25 50.000 Label Fragrant Lemon 250ml
FL500 BS01 12.000 Base Shampoo
FL500 BT500 24.000 Bottle 500ml
FL500 CAPS 24.000 Screw cap
FL500 CARL 1.000 Carton large
FL500 ESL 0.120 Lemon essence
FL500 LFL50 26.000 Label Fragrant Lemon 500ml
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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-00
BS01 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
BT250 Bottle 250ml BP01 Best Plastics 40,000 1-Apr-00
BT250 Bottle 250ml BP01 Best Plastics 50,000 22-Apr-00
BT500 Bottle 500ml BP01 Best Plastics 100,000 16-Mar-00
BT500 Bottle 500ml BP01 Best Plastics 50,000 1-Apr-00
BT500 Bottle 500ml BP01 Best Plastics 50,000 15-Apr-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-00
CARL 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-00
LAB50 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
LFL10 Label Fragrant Lemon 100ml DP01 Dave's Printing 10,000 28-Apr-00
LFL25 Label Fragrant Lemon 250ml DP01 Dave's Printing 60,000 17-Mar-00
LFL25 Label Fragrant Lemon 250ml DP01 Dave's Printing 60,000 31-Mar-00
LFL50 Label Fragrant Lemon 500ml DP01 Dave's Printing 40,000 30-Mar-00
LFL50 Label Fragrant Lemon 500ml DP01 Dave's Printing 40,000 13-Apr-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
www.production-scheduling.com

Start of the first job: 14/3 8:00 AB100 AB250 AB500 FL100 FL250 FL500 AB100 AB250 AB500 FL100 FL250 FL500
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 1,600
Min 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

Produc Idle Run Lowest Offs Next Invento For- Min Min Max To
t Force Qty Force hours Force hours Start Stop Projected Inventory - units Projected Cover - weeks Cover et Prod ry Speed cast Cover cartons cartons make
Opening stock: 14/3 8:00 1,854 1,470 470 488 1,148 766 1.85 1.05 0.59 2.44 0.96 0.48
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 0.72 2.44 0.95 0.48 0.48 6 FL500 760 175 1600 0.5 800 3200 2580
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 0.63 2.35 0.87 2.00 0.63 3 AB500 507 175 800 0.5 400 1600 1124
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 0.50 2.22 0.73 1.87 0.50 3 AB500 400 175 800 0.5 400 1600 1234
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 2.00 2.17 0.69 1.82 0.69 5 FL250 828 87.5 1200 0.5 600 2400 1712
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 1.81 1.98 0.50 1.63 0.50 5 FL250 600 87.5 1200 0.5 600 2400 1960
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 1.68 1.85 2.00 1.50 0.46 2 AB250 644 87.5 1400 0.5 700 2800 2383
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 1.52 1.69 1.84 1.34 1.10 1 AB100 1102 87.5 1000 0.5 500 2000 964
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 0.91 1.09 1.24 0.74 0.50 1 AB100 500 87.5 1000 0.5 500 2000 1609
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 0.80 0.98 1.13 0.63 0.63 6 FL500 1004 175 1600 0.5 800 3200 2322
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 0.68 0.85 1.00 0.50 0.50 6 FL500 800 175 1600 0.5 800 3200 2538
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 0.59 0.76 0.91 2.00 0.59 3 AB500 472 175 800 0.5 400 1600 1160
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 0.50 0.67 0.82 1.91 0.50 3 AB500 400 175 800 0.5 400 1600 1234
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 2.00 0.63 0.78 1.87 0.63 4 FL100 126 87.5 200 0.5 100 400 278
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 1.87 0.50 0.65 1.74 0.50 4 FL100 100 87.5 200 0.5 100 400 304
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 1.85 2.00 0.63 1.72 0.63 5 FL250 755 87.5 1200 0.5 600 2400 1791
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 1.72 1.87 0.50 1.59 0.50 5 FL250 600 87.5 1200 0.5 600 2400 1960
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 1.59 1.74 2.00 1.45 0.53 2 AB250 740 87.5 1400 0.5 700 2800 2276
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 1.56 1.71 1.97 1.43 0.50 2 AB250 700 87.5 1400 0.5 700 2800 2321
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 1.40 1.55 1.81 1.27 1.05 1 AB100 1053 87.5 1000 0.5 500 2000 1016
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 0.85 1.00 1.26 0.71 0.50 1 AB100 500 87.5 1000 0.5 500 2000 1609
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 0.74 0.89 1.15 0.61 0.61 6 FL500 968 175 1600 0.5 800 3200 2360
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 0.63 0.78 1.05 0.50 0.50 6 FL500 800 175 1600 0.5 800 3200 2538
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 1.15 0.55 0.70 0.96 2.00 0.55 3 AB500 437 175 800 0.5 400 1600 1196
Idle 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 0.50 0.65 0.91 1.95 0.50 3 AB500 400 175 800 0.5 400 1600 1234

3.00
Projected Inventory
2.50 Cover
Weeks

2.00

1.50 AB100
AB250
AB500
1.00
FL100
FL250
0.50 FL500

0.00
10/3 0:00 15/3 0:00 20/3 0:00 25/3 0:00 30/3 0:00 4/4 0:00 9/4 0:00
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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
- 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.
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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 of Qty
Prod/Run Prod Product Start Total Run
AB100/1 AB100 AB100 ### 1609 1
AB100/2 AB100 4/4/2000 1:47 1609 2
AB250/1 AB250 AB250 ### 2383 1
AB250/2 AB250 3/30/2000 2:21 2321 2
AB500/1 AB500 AB500 3/14/2000 8:00 110 1
AB500/2 AB500 ### 1234 2
AB500/3 AB500 ### 1234 3
FL100/1 FL100 FL100 ### 304 1
FL250/1 FL250 FL250 ### 1960 1
FL250/2 FL250 ### 1960 2
FL500/1 FL500 FL500 3/14/2000 8:37 2580 1
FL500/2 FL500 ### 2538 2
FL500/3 FL500 4/5/2000 13:49 2538 3
Grand Total 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
Product/ Qty Production Production Quantity
Run Component each Run Index Start Date Qty Required
AB100/1 BS01 4.8 6 23-Mar-00 1609 7723.2
AB100/1 BT100 48 6 23-Mar-00 1609 77232
AB100/1 CAPF 48 6 23-Mar-00 1609 77232
AB100/1 CARS 1 6 23-Mar-00 1609 1609
AB100/1 ESA 0.048 6 23-Mar-00 1609 77.232
AB100/1 LAB10 50 6 23-Mar-00 1609 80450
AB250/1 BS01 12 8 18-Mar-00 2383 28596
AB250/1 BT250 48 8 18-Mar-00 2383 114384
AB250/1 CAPF 48 8 18-Mar-00 2383 114384
AB250/1 CARL 1 8 18-Mar-00 2383 2383
AB250/1 ESA 0.12 8 18-Mar-00 2383 285.96
AB250/1 LAB25 50 8 18-Mar-00 2383 119150
AB500/1 BS01 12 10 14-Mar-00 110 1320
AB500/1 BT500 24 10 14-Mar-00 110 2640
AB500/1 CAPS 24 10 14-Mar-00 110 2640
AB500/1 CARL 1 10 14-Mar-00 110 110
AB500/1 ESA 0.12 10 14-Mar-00 110 13.2
AB500/1 LAB50 26 10 14-Mar-00 110 2860
FL100/1 BS01 4.8 13 27-Mar-00 304 1459.2
FL100/1 BT100 48 13 27-Mar-00 304 14592
FL100/1 CAPF 48 13 27-Mar-00 304 14592
FL100/1 CARS 1 13 27-Mar-00 304 304
FL100/1 ESL 0.048 13 27-Mar-00 304 14.592
FL100/1 LFL10 50 13 27-Mar-00 304 15200
FL250/1 BS01 12 14 17-Mar-00 1960 23520
FL250/1 BT250 48 14 17-Mar-00 1960 94080
FL250/1 CAPF 48 14 17-Mar-00 1960 94080
FL250/1 CARL 1 14 17-Mar-00 1960 1960
FL250/1 ESL 0.12 14 17-Mar-00 1960 235.2
FL250/1 LFL25 50 14 17-Mar-00 1960 98000
FL500/1 BS01 12 16 14-Mar-00 2580 30960
FL500/1 BT500 24 16 14-Mar-00 2580 61920
FL500/1 CAPS 24 16 14-Mar-00 2580 61920
FL500/1 CARL 1 16 14-Mar-00 2580 2580
FL500/1 ESL 0.12 16 14-Mar-00 2580 309.6
FL500/1 LFL50 26 16 14-Mar-00 2580 67080
/1 0 0 #N/A 30-Dec-99 0 0
/1 0 0 #N/A 30-Dec-99 0 0
/1 0 0 #N/A 30-Dec-99 0 0
/1 0 0 #N/A 30-Dec-99 0 0
/1 0 0 #N/A 30-Dec-99 0 0
/1 0 0 #N/A 30-Dec-99 0 0
/1 0 0 #N/A 30-Dec-99 0 0
/1 0 0 #N/A 30-Dec-99 0 0
/1 0 0 #N/A 30-Dec-99 0 0
/1 0 0 #N/A 30-Dec-99 0 0
AB100/2 BS01 4.8 7 4-Apr-00 1609 7723.2
AB100/2 BT100 48 7 4-Apr-00 1609 77232
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AB100/2 CAPF 48 7 4-Apr-00 1609 77232

AB100/2 CARS 1 7 4-Apr-00 1609 1609
AB100/2 ESA 0.048 7 4-Apr-00 1609 77.232
AB100/2 LAB10 50 7 4-Apr-00 1609 80450
AB250/2 BS01 12 9 30-Mar-00 2321 27852
AB250/2 BT250 48 9 30-Mar-00 2321 111408
AB250/2 CAPF 48 9 30-Mar-00 2321 111408
AB250/2 CARL 1 9 30-Mar-00 2321 2321
AB250/2 ESA 0.12 9 30-Mar-00 2321 278.52
AB250/2 LAB25 50 9 30-Mar-00 2321 116050
AB500/2 BS01 12 11 15-Mar-00 1234 14808
AB500/2 BT500 24 11 15-Mar-00 1234 29616
AB500/2 CAPS 24 11 15-Mar-00 1234 29616
AB500/2 CARL 1 11 15-Mar-00 1234 1234
AB500/2 ESA 0.12 11 15-Mar-00 1234 148.08
AB500/2 LAB50 26 11 15-Mar-00 1234 32084
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 0.048 #N/A 30-Dec-99 0 0
FL100/2 LFL10 50 #N/A 30-Dec-99 0 0
FL250/2 BS01 12 15 28-Mar-00 1960 23520
FL250/2 BT250 48 15 28-Mar-00 1960 94080
FL250/2 CAPF 48 15 28-Mar-00 1960 94080
FL250/2 CARL 1 15 28-Mar-00 1960 1960
FL250/2 ESL 0.12 15 28-Mar-00 1960 235.2
FL250/2 LFL25 50 15 28-Mar-00 1960 98000
FL500/2 BS01 12 17 25-Mar-00 2538 30456
FL500/2 BT500 24 17 25-Mar-00 2538 60912
FL500/2 CAPS 24 17 25-Mar-00 2538 60912
FL500/2 CARL 1 17 25-Mar-00 2538 2538
FL500/2 ESL 0.12 17 25-Mar-00 2538 304.56
FL500/2 LFL50 26 17 25-Mar-00 2538 65988
/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 0
AB100/3 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 0.048 #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
 http://www.production-scheduling.com

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 12 26-Mar-00 1234 14808
AB500/3 BT500 24 12 26-Mar-00 1234 29616
AB500/3 CAPS 24 12 26-Mar-00 1234 29616
AB500/3 CARL 1 12 26-Mar-00 1234 1234
AB500/3 ESA 0.12 12 26-Mar-00 1234 148.08
AB500/3 LAB50 26 12 26-Mar-00 1234 32084
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 0
FL100/3 CARS 1 #N/A 30-Dec-99 0 0
FL100/3 ESL 0.048 #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 18 5-Apr-00 2538 30456
FL500/3 BT500 24 18 5-Apr-00 2538 60912
FL500/3 CAPS 24 18 5-Apr-00 2538 60912
FL500/3 CARL 1 18 5-Apr-00 2538 2538
FL500/3 ESL 0.12 18 5-Apr-00 2538 304.56
FL500/3 LFL50 26 18 5-Apr-00 2538 65988
/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
 http://www.production-scheduling.com

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

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 23-Mar-00 AB100/1 1609 CARS 23-Mar-00 27 Carton small
27-Mar-00 FL100/1 304 CARS 27-Mar-00 27 Carton small
4-Apr-00 AB100/2 1609 CARS 4-Apr-00 27 Carton small
ESA 14-Mar-00 AB500/1 13.2 ESA 14-Mar-00 14 Apple essence
15-Mar-00 AB500/2 148.08 ESA 15-Mar-00 14 Apple essence
18-Mar-00 AB250/1 285.96 ESA 18-Mar-00 14 Apple essence
23-Mar-00 AB100/1 77.232 ESA 23-Mar-00 14 Apple essence
26-Mar-00 AB500/3 148.08 ESA 26-Mar-00 14 Apple essence
30-Mar-00 AB250/2 278.52 ESA 30-Mar-00 14 Apple essence
4-Apr-00 AB100/2 77.232 ESA 4-Apr-00 14 Apple essence
ESL 14-Mar-00 FL500/1 309.6 ESL 14-Mar-00 15 Lemon essence
17-Mar-00 FL250/1 235.2 ESL 17-Mar-00 15 Lemon essence
25-Mar-00 FL500/2 304.56 ESL 25-Mar-00 15 Lemon essence
27-Mar-00 FL100/1 14.592 ESL 27-Mar-00 15 Lemon essence
28-Mar-00 FL250/2 235.2 ESL 28-Mar-00 15 Lemon essence
5-Apr-00 FL500/3 304.56 ESL 5-Apr-00 15 Lemon essence
LAB10 23-Mar-00 AB100/1 80450 LAB10 23-Mar-00 21 Label Apple Blossom 1
4-Apr-00 AB100/2 80450 LAB10 4-Apr-00 21 Label Apple Blossom 1
LAB25 18-Mar-00 AB250/1 119150 LAB25 18-Mar-00 22 Label Apple Blossom 2
30-Mar-00 AB250/2 116050 LAB25 30-Mar-00 22 Label Apple Blossom 2
LAB50 14-Mar-00 AB500/1 2860 LAB50 14-Mar-00 23 Label Apple Blossom 5
15-Mar-00 AB500/2 32084 LAB50 15-Mar-00 23 Label Apple Blossom 5
26-Mar-00 AB500/3 32084 LAB50 26-Mar-00 23 Label Apple Blossom 5
LFL10 27-Mar-00 FL100/1 15200 LFL10 27-Mar-00 24 Label Fragrant Lemon
LFL25 17-Mar-00 FL250/1 98000 LFL25 17-Mar-00 25 Label Fragrant Lemon
28-Mar-00 FL250/2 98000 LFL25 28-Mar-00 25 Label Fragrant Lemon
LFL50 14-Mar-00 FL500/1 67080 LFL50 14-Mar-00 26 Label Fragrant Lemon
25-Mar-00 FL500/2 65988 LFL50 25-Mar-00 26 Label Fragrant Lemon
5-Apr-00 FL500/3 65988 LFL50 5-Apr-00 26 Label Fragrant Lemon
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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 250ml
BT250 22-Apr-00 Bottle 250ml
BT500 16-Mar-00 Bottle 500ml
BT500 1-Apr-00 Bottle 500ml
BT500 15-Apr-00 Bottle 500ml
CAPF 16-Mar-00 Flip cap
CAPF 7-Apr-00 Flip cap
CAPS 17-Mar-00 Screw cap
http://www.production-scheduling.com

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 small
ESA 23-Mar-00 Apple essence
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 5
LAB50 30-Apr-00 Label Apple Blossom 5
LFL10 14-Apr-00 Label Fragrant Lemon
LFL10 28-Apr-00 Label Fragrant Lemon
LFL25 17-Mar-00 Label Fragrant Lemon
LFL25 31-Mar-00 Label Fragrant Lemon
LFL50 30-Mar-00 Label Fragrant Lemon
LFL50 13-Apr-00 Label Fragrant Lemon
 http://www.production-scheduling.com

5 6 8

Balance
Supplier Supplier Name Inventory Remaining Get In On order
AC01 Ace Chemicals 34,276 32,956 0
AC01 Ace Chemicals 34,276 1,996 0
AC01 Ace Chemicals 34,276 -12,812 12,812
AC01 Ace Chemicals 34,276 -36,332 23,520
AC01 Ace Chemicals 34,276 -64,928 28,596
AC01 Ace Chemicals 34,276 -72,651 7,723
AC01 Ace Chemicals 34,276 -103,107 30,456
AC01 Ace Chemicals 34,276 -117,915 14,808
AC01 Ace Chemicals 34,276 -119,374 1,459
AC01 Ace Chemicals 34,276 -142,894 23,520
AC01 Ace Chemicals 34,276 -170,746 27,852
AC01 Ace Chemicals 34,276 -178,470 7,723
AC01 Ace Chemicals 34,276 -208,926 30,456
BP01 Best Plastics 122,472 45,240 0
BP01 Best Plastics 122,472 30,648 0
BP01 Best Plastics 122,472 -46,584 46,584
BP01 Best Plastics 184,968 90,888 0
BP01 Best Plastics 184,968 -23,496 23,496
BP01 Best Plastics 184,968 -117,576 94,080
BP01 Best Plastics 184,968 -228,984 111,408
BP01 Best Plastics 36,516 33,876 0
BP01 Best Plastics 36,516 -28,044 28,044
BP01 Best Plastics 36,516 -57,660 29,616
BP01 Best Plastics 36,516 -118,572 60,912
BP01 Best Plastics 36,516 -148,188 29,616
BP01 Best Plastics 36,516 -209,100 60,912
BP01 Best Plastics 65,738 -28,342 28,342
BP01 Best Plastics 65,738 -142,726 114,384
BP01 Best Plastics 65,738 -219,958 77,232
BP01 Best Plastics 65,738 -234,550 14,592
BP01 Best Plastics 65,738 -328,630 94,080
BP01 Best Plastics 65,738 -440,038 111,408
BP01 Best Plastics 65,738 -517,270 77,232
BP01 Best Plastics 37,818 35,178 0
BP01 Best Plastics 37,818 -26,742 26,742
BP01 Best Plastics 37,818 -56,358 29,616
BP01 Best Plastics 37,818 -117,270 60,912
BP01 Best Plastics 37,818 -146,886 29,616
BP01 Best Plastics 37,818 -207,798 60,912
EC01 Eduardo Corrugates 4,368 4,258 0
EC01 Eduardo Corrugates 4,368 1,678 0
EC01 Eduardo Corrugates 4,368 444 0
EC01 Eduardo Corrugates 4,368 -1,516 1,516
EC01 Eduardo Corrugates 4,368 -3,899 2,383
EC01 Eduardo Corrugates 4,368 -6,437 2,538
EC01 Eduardo Corrugates 4,368 -7,671 1,234
EC01 Eduardo Corrugates 4,368 -9,631 1,960
 http://www.production-scheduling.com

EC01 Eduardo Corrugates 4,368 -11,952 2,321

EC01 Eduardo Corrugates 4,368 -14,490 2,538
EC01 Eduardo Corrugates 998 -611 611
EC01 Eduardo Corrugates 998 -915 304
EC01 Eduardo Corrugates 998 -2,524 1,609
CE01 Chang Essences 1,494 1,481 0
CE01 Chang Essences 1,494 1,333 0
CE01 Chang Essences 1,494 1,047 0
CE01 Chang Essences 1,494 970 0
CE01 Chang Essences 1,494 821 0
CE01 Chang Essences 1,494 543 0
CE01 Chang Essences 1,494 466 0
CE01 Chang Essences 1,002 692 0
CE01 Chang Essences 1,002 457 0
CE01 Chang Essences 1,002 153 0
CE01 Chang Essences 1,002 138 0
CE01 Chang Essences 1,002 -97 97
CE01 Chang Essences 1,002 -402 305
DP01 Dave's Printing 211,796 131,346 0
DP01 Dave's Printing 211,796 50,896 0
DP01 Dave's Printing 266,776 147,626 0
DP01 Dave's Printing 266,776 31,576 0
DP01 Dave's Printing 24,964 22,104 0
DP01 Dave's Printing 24,964 -9,980 9,980
DP01 Dave's Printing 24,964 -42,064 32,084
DP01 Dave's Printing 32,140 16,940 0
DP01 Dave's Printing 83,496 -14,504 14,504
DP01 Dave's Printing 83,496 -112,504 98,000
DP01 Dave's Printing 117,354 50,274 0
DP01 Dave's Printing 117,354 -15,714 15,714
DP01 Dave's Printing 117,354 -81,702 65,988
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AC01 Ace Chemicals 100,000
AC01 Ace Chemicals 100,000
BP01 Best Plastics 40,000
BP01 Best Plastics 90,000
BP01 Best Plastics 40,000
BP01 Best Plastics 50,000
BP01 Best Plastics 100,000
BP01 Best Plastics 50,000
BP01 Best Plastics 50,000
BP01 Best Plastics 200,000
BP01 Best Plastics 300,000
BP01 Best Plastics 100,000
 http://www.production-scheduling.com

BP01 Best Plastics 100,000

EC01 Eduardo Corrugates 8,000
EC01 Eduardo Corrugates 5,000
EC01 Eduardo Corrugates 1,000
EC01 Eduardo Corrugates 1,000
CE01 Chang Essences 60
CE01 Chang Essences 100
CE01 Chang Essences 350
DP01 Dave's Printing 50,000
DP01 Dave's Printing 70,000
DP01 Dave's Printing 60,000
DP01 Dave's Printing 20,000
DP01 Dave's Printing 20,000
DP01 Dave's Printing 20,000
DP01 Dave's Printing 10,000
DP01 Dave's Printing 10,000
DP01 Dave's Printing 60,000
DP01 Dave's Printing 60,000
DP01 Dave's Printing 40,000
DP01 Dave's Printing 40,000
Purchase Action Report

Data Balance
Supplier Name Description Start Date Product/Run Get In On order
Ace Chemicals Base Sham 14-Mar-00 AB500/1 0 0
FL500/1 0 0
15-Mar-00 AB500/2 12,812 -12,812
17-Mar-00 FL250/1 23,520 -36,332
18-Mar-00 AB250/1 28,596 -64,928
23-Mar-00 AB100/1 7,723 -72,651
25-Mar-00 FL500/2 30,456 -103,107
26-Mar-00 AB500/3 14,808 -117,915
27-Mar-00 FL100/1 1,459 -119,374
28-Mar-00 FL250/2 23,520 -142,894
30-Mar-00 AB250/2 27,852 -170,746
4-Apr-00 AB100/2 7,723 -178,470
5-Apr-00 FL500/3 30,456 -208,926
208,926 -417,851
Best Plastics Bottle 100ml23-Mar-00 AB100/1 0 -417,851
27-Mar-00 FL100/1 0 -417,851
4-Apr-00 AB100/2 46,584 -464,435
46,584 -511,019
Bottle 250ml17-Mar-00 FL250/1 0 -511,019
18-Mar-00 AB250/1 23,496 -534,515
28-Mar-00 FL250/2 94,080 -628,595
30-Mar-00 AB250/2 111,408 -740,003
228,984 -968,987
Bottle 500ml14-Mar-00 AB500/1 0 -968,987
FL500/1 28,044 -997,031
15-Mar-00 AB500/2 29,616 ###
25-Mar-00 FL500/2 60,912 ###
26-Mar-00 AB500/3 29,616 ###
5-Apr-00 FL500/3 60,912 ###
209,100 ###
Flip cap 17-Mar-00 FL250/1 28,342 ###
18-Mar-00 AB250/1 114,384 ###
23-Mar-00 AB100/1 77,232 ###
27-Mar-00 FL100/1 14,592 ###
28-Mar-00 FL250/2 94,080 ###
30-Mar-00 AB250/2 111,408 ###
4-Apr-00 AB100/2 77,232 ###
517,270 ###
Screw cap 14-Mar-00 AB500/1 0 ###
FL500/1 26,742 ###
15-Mar-00 AB500/2 29,616 ###
25-Mar-00 FL500/2 60,912 ###
26-Mar-00 AB500/3 29,616 ###
5-Apr-00 FL500/3 60,912 ###
207,798 ###
Chang Essence Apple essen14-Mar-00 AB500/1 0 ###
15-Mar-00 AB500/2 0 ###
18-Mar-00 AB250/1 0 ###
23-Mar-00 AB100/1 0 ###
26-Mar-00 AB500/3 0 ###
30-Mar-00 AB250/2 0 ###

http://www.production-scheduling.com Page 25 of 34
Purchase Action Report

Data Balance
Supplier Name Description Start Date Product/Run Get In On order
4-Apr-00 AB100/2 0 ###
0 ###
Lemon esse14-Mar-00 FL500/1 0 ###
17-Mar-00 FL250/1 0 ###
25-Mar-00 FL500/2 0 ###
27-Mar-00 FL100/1 0 ###
28-Mar-00 FL250/2 97 ###
5-Apr-00 FL500/3 305 ###
402 ###
Dave's Printing Label Apple 23-Mar-00 AB100/1 0 ###
4-Apr-00 AB100/2 0 ###
0 ###
Label Apple 18-Mar-00 AB250/1 0 ###
30-Mar-00 AB250/2 0 ###
0 ###
Label Apple 14-Mar-00 AB500/1 0 ###
15-Mar-00 AB500/2 9,980 ###
26-Mar-00 AB500/3 32,084 ###
42,064 ###
Label Fragr 27-Mar-00 FL100/1 0 ###
0 ###
Label Fragr 17-Mar-00 FL250/1 14,504 ###
28-Mar-00 FL250/2 98,000 ###
112,504 ###
Label Fragr 14-Mar-00 FL500/1 0 ###
25-Mar-00 FL500/2 15,714 ###
5-Apr-00 FL500/3 65,988 ###
81,702 ###
Eduardo Corrug Carton large14-Mar-00 AB500/1 0 ###
FL500/1 0 ###
15-Mar-00 AB500/2 0 ###
17-Mar-00 FL250/1 1,516 ###
18-Mar-00 AB250/1 2,383 ###
25-Mar-00 FL500/2 2,538 ###
26-Mar-00 AB500/3 1,234 ###
28-Mar-00 FL250/2 1,960 ###
30-Mar-00 AB250/2 2,321 ###
5-Apr-00 FL500/3 2,538 ###
14,490 ###
Carton smal 23-Mar-00 AB100/1 611 ###
27-Mar-00 FL100/1 304 ###
4-Apr-00 AB100/2 1,609 ###
2,524 ###
###
###
###
###

http://www.production-scheduling.com Page 26 of 34
 http://www.production-scheduling.com

Inventory Rationing Logic

 http://www.production-scheduling.com

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?"

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
Components
P Pivot
Inventory
Rationing
Calculation
P
Products Pivot

Formula link: F
PivotTable link: 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
 http://www.production-scheduling.com

8 8

Bill of Materials First Pass Calculations

Product Product Component Total Total Total Product

Sales Inventory Sales Component Components Components Average Cover Min
Forcast Product Cover Forcast per Sales Components in Product in Product Inventory Below Average Make
Product Component Qty Component Description per Week Inventory Weeks Week Forecast in Inventory Inventory Inventory Cover Average Cover Weeks
AB100 BS01 4.800 Base Shampoo 1000 1854 1.85 #VALUE! #VALUE! 34276 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB100 BT100 48.000 Bottle 100ml 1000 1854 1.85 #VALUE! #VALUE! 122472 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB100 CAPF 48.000 Flip cap 1000 1854 1.85 #VALUE! #VALUE! 65738 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB100 CARS 1.000 Carton small 1000 1854 1.85 #VALUE! #VALUE! 998 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB100 ESA 0.048 Apple essence 1000 1854 1.85 #VALUE! #VALUE! 1494 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB100 LAB10 50.000 Label Apple Blossom 100ml 1000 1854 1.85 #VALUE! #VALUE! 211796 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB250 BS01 12.000 Base Shampoo 1400 1470 1.05 #VALUE! #VALUE! 34276 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB250 BT250 48.000 Bottle 250ml 1400 1470 1.05 #VALUE! #VALUE! 184968 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB250 CAPF 48.000 Flip cap 1400 1470 1.05 #VALUE! #VALUE! 65738 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB250 CARL 1.000 Carton large 1400 1470 1.05 #VALUE! #VALUE! 4368 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB250 ESA 0.120 Apple essence 1400 1470 1.05 #VALUE! #VALUE! 1494 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB250 LAB25 50.000 Label Apple Blossom 250ml 1400 1470 1.05 #VALUE! #VALUE! 266776 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB500 BS01 12.000 Base Shampoo 800 470 0.59 #VALUE! #VALUE! 34276 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB500 BT500 24.000 Bottle 500ml 800 470 0.59 #VALUE! #VALUE! 36516 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB500 CAPS 24.000 Screw cap 800 470 0.59 #VALUE! #VALUE! 37818 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB500 CARL 1.000 Carton large 800 470 0.59 #VALUE! #VALUE! 4368 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB500 ESA 0.120 Apple essence 800 470 0.59 #VALUE! #VALUE! 1494 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
AB500 LAB50 26.000 Label Apple Blossom 500ml 800 470 0.59 #VALUE! #VALUE! 24964 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL100 BS01 4.800 Base Shampoo 200 488 2.44 #VALUE! #VALUE! 34276 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL100 BT100 48.000 Bottle 100ml 200 488 2.44 #VALUE! #VALUE! 122472 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL100 CAPF 48.000 Flip cap 200 488 2.44 #VALUE! #VALUE! 65738 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL100 CARS 1.000 Carton small 200 488 2.44 #VALUE! #VALUE! 998 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL100 ESL 0.048 Lemon essence 200 488 2.44 #VALUE! #VALUE! 1002 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL100 LFL10 50.000 Label Fragrant Lemon 100ml 200 488 2.44 #VALUE! #VALUE! 32140 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL250 BS01 12.000 Base Shampoo 1200 1148 0.96 #VALUE! #VALUE! 34276 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL250 BT250 48.000 Bottle 250ml 1200 1148 0.96 #VALUE! #VALUE! 184968 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL250 CAPF 48.000 Flip cap 1200 1148 0.96 #VALUE! #VALUE! 65738 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL250 CARL 1.000 Carton large 1200 1148 0.96 #VALUE! #VALUE! 4368 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL250 ESL 0.120 Lemon essence 1200 1148 0.96 #VALUE! #VALUE! 1002 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL250 LFL25 50.000 Label Fragrant Lemon 250ml 1200 1148 0.96 #VALUE! #VALUE! 83496 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL500 BS01 12.000 Base Shampoo 1600 766 0.48 #VALUE! #VALUE! 34276 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL500 BT500 24.000 Bottle 500ml 1600 766 0.48 #VALUE! #VALUE! 36516 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL500 CAPS 24.000 Screw cap 1600 766 0.48 #VALUE! #VALUE! 37818 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL500 CARL 1.000 Carton large 1600 766 0.48 #VALUE! #VALUE! 4368 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL500 ESL 0.120 Lemon essence 1600 766 0.48 #VALUE! #VALUE! 1002 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
FL500 LFL50 26.000 Label Fragrant Lemon 500ml 1600 766 0.48 #VALUE! #VALUE! 117354 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! ###
 http://www.production-scheduling.com

Second Pass Calculations

Total
Total Compone Compone
Product Component Compone Compone nts in nts in Total Product Compone
Product Inventory Sales nt Sales nts in Product Product Average Cover Min Use Total Use nts in
Make Use Total Use Inventory Cover Forcast per Forecast Inventory Inventory Inventory Inventory Below Average Make Make Compone Compone Inventory
Product Component Component 2 Weeks 2 Week 2 2 2 2 2 Cover 2 Average 2 Cover 2 Weeks 2 Product 2 nt 2 nt 2 3
#VALUE! #VALUE! 28714 #VALUE! #VALUE! #VALUE! 4800 5562 #VALUE! 2342.4 1.65 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 2391.208 3170
#VALUE! #VALUE! 0 #VALUE! #VALUE! #VALUE! 48000 122472 #VALUE! 23424 3.04 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 23912.08 98560
#VALUE! #VALUE! 41826 #VALUE! #VALUE! #VALUE! 48000 23912 #VALUE! 23424 0.99 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 23912.08 0
#VALUE! #VALUE! 0 #VALUE! #VALUE! #VALUE! 1000 998 #VALUE! 488 1.49 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 498.1683 500
#VALUE! #VALUE! 103 #VALUE! #VALUE! #VALUE! 48 1391 #VALUE! 0 28.98 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 1391
#VALUE! #VALUE! 0 #VALUE! #VALUE! #VALUE! 50000 211796 #VALUE! 0 4.24 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 211796
#VALUE! #VALUE! 28714 #VALUE! #VALUE! #VALUE! 16800 5562 #VALUE! 2342.4 0.47 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 2391.208 3170
#VALUE! #VALUE! 41826 #VALUE! #VALUE! #VALUE! 67200 143142 #VALUE! 0 2.13 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 143142
#VALUE! #VALUE! 41826 #VALUE! #VALUE! #VALUE! 67200 23912 #VALUE! 23424 0.70 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 23912.08 0
#VALUE! #VALUE! 2393 #VALUE! #VALUE! #VALUE! 1400 1975 #VALUE! 0 1.41 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 1975
#VALUE! #VALUE! 103 #VALUE! #VALUE! #VALUE! 168 1391 #VALUE! 0 8.28 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 1391
#VALUE! #VALUE! 20445 #VALUE! #VALUE! #VALUE! 70000 246331 #VALUE! 0 3.52 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 246331
#VALUE! #VALUE! 28714 #VALUE! #VALUE! #VALUE! 9600 5562 #VALUE! 2342.4 0.82 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 2391.208 3170
#VALUE! #VALUE! 36516 #VALUE! #VALUE! #VALUE! 19200 0 #VALUE! 0 0.00 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 0
#VALUE! #VALUE! 36516 #VALUE! #VALUE! #VALUE! 19200 1302 #VALUE! 0 0.07 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 1302
#VALUE! #VALUE! 2393 #VALUE! #VALUE! #VALUE! 800 1975 #VALUE! 0 2.47 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 1975
#VALUE! #VALUE! 103 #VALUE! #VALUE! #VALUE! 96 1391 #VALUE! 0 14.49 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 1391
#VALUE! #VALUE! 11678 #VALUE! #VALUE! #VALUE! 20800 13286 #VALUE! 0 0.64 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 13286
#VALUE! #VALUE! 28714 #VALUE! #VALUE! #VALUE! 960 5562 #VALUE! 2342.4 8.23 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 2391.208 3170
#VALUE! #VALUE! 0 #VALUE! #VALUE! #VALUE! 9600 122472 #VALUE! 23424 15.20 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 23912.08 98560
#VALUE! #VALUE! 41826 #VALUE! #VALUE! #VALUE! 9600 23912 #VALUE! 23424 4.93 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 23912.08 0
#VALUE! #VALUE! 0 #VALUE! #VALUE! #VALUE! 200 998 #VALUE! 488 7.43 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 498.1683 500
#VALUE! #VALUE! 184 #VALUE! #VALUE! #VALUE! 9.6 818 #VALUE! 23.424 87.63 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 23.91208 794
#VALUE! #VALUE! 0 #VALUE! #VALUE! #VALUE! 10000 32140 #VALUE! 24400 5.65 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 24908.42 7232
#VALUE! #VALUE! 28714 #VALUE! #VALUE! #VALUE! 14400 5562 #VALUE! 2342.4 0.55 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 2391.208 3170
#VALUE! #VALUE! 41826 #VALUE! #VALUE! #VALUE! 57600 143142 #VALUE! 0 2.49 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 143142
#VALUE! #VALUE! 41826 #VALUE! #VALUE! #VALUE! 57600 23912 #VALUE! 23424 0.82 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 23912.08 0
#VALUE! #VALUE! 2393 #VALUE! #VALUE! #VALUE! 1200 1975 #VALUE! 0 1.65 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 1975
#VALUE! #VALUE! 184 #VALUE! #VALUE! #VALUE! 144 818 #VALUE! 23.424 5.84 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 23.91208 794
#VALUE! #VALUE! 23124 #VALUE! #VALUE! #VALUE! 60000 60372 #VALUE! 0 1.01 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 60372
#VALUE! #VALUE! 28714 #VALUE! #VALUE! #VALUE! 19200 5562 #VALUE! 2342.4 0.41 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 2391.208 3170
#VALUE! #VALUE! 36516 #VALUE! #VALUE! #VALUE! 38400 0 #VALUE! 0 0.00 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 0
#VALUE! #VALUE! 36516 #VALUE! #VALUE! #VALUE! 38400 1302 #VALUE! 0 0.03 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 1302
#VALUE! #VALUE! 2393 #VALUE! #VALUE! #VALUE! 1600 1975 #VALUE! 0 1.23 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 1975
#VALUE! #VALUE! 184 #VALUE! #VALUE! #VALUE! 192 818 #VALUE! 23.424 4.38 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 23.91208 794
#VALUE! #VALUE! 27881 #VALUE! #VALUE! #VALUE! 41600 89473 #VALUE! 0 2.15 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 89473
 http://www.production-scheduling.com

Make
Product
1+2
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
 http://www.production-scheduling.com

Data

Component Sum of Compone

Sum of Compon
Sum of Use C Sum of ComponeSum of ComponenSum of Use Component 2
BS01 #VALUE! #VALUE! 28714.48 960 2342.4 2391.208
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! 2392.873333 0 0 0
CARS #VALUE! #VALUE! 0 200 488 498.1683333
ESA #VALUE! #VALUE! 102.9672 0 0 0
ESL #VALUE! #VALUE! 184.1776 9.6 23.424 23.91208
LAB10 #VALUE! #VALUE! 0 0 0 0
LAB25 #VALUE! #VALUE! 20444.66667 0 0 0
LAB50 #VALUE! #VALUE! 11678.33333 0 0 0
LFL10 #VALUE! #VALUE! 0 10000 24400 24908.41667
LFL25 #VALUE! #VALUE! 23124 0 0 0
LFL50 #VALUE! #VALUE! 27880.66667 0 0 0
 http://www.production-scheduling.com

um of Use Component 2
 http://www.production-scheduling.com

Data

Product Min of Total Av Min of Total Av Product to make with components in inventory
AB100 #VALUE! #VALUE! 0
AB250 #VALUE! #VALUE! 2454
AB500 #VALUE! #VALUE! 2694
FL100 #VALUE! #VALUE! 2988
FL250 #VALUE! #VALUE! 2772
FL500 #VALUE! #VALUE! 6432