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Best way to structure manufacturing/MRP flows [SOLVED]
05-05-2017, 11:54 AM, (This post was last modified: 06-07-2017, 11:10 PM by trentmurgatroyd.)
#1
Best way to structure manufacturing/MRP flows [SOLVED]
We make up products using mixed raw materials.
We do a premix at our facility - based on the same/similar raw materials as we send out,but in small, specific/exact recipe amounts.
We then send the pre-mix, along with the bulk bags to the main blend plant(s). They process it and send back finished product and leftovers.

I will try to describe a simplified example.

A) our "shop" issues work order for 25x2kg buckets of "x" to our Store/Lab

B) our Store/Lab. (has raw materials from suppliers. Also makes up small pre-mixes)
Raw Materials: eg. 10x20kg bags of sugar, 10x10kg bags of salt, 1x1kg bag of colourant, 2x1kg bags of flavour, 100 (empty) buckets.

We make premix1 eg. 1.3kg sugar + 0.085kg colourant = 1.385kg
We make premix2 eg. 0.66kg flavour + 0.455kg salt = 1.115kg
LabMix=premix1+premix2=2.5kg

C) Blend Plant (external service provider)
The "macro-recipe" is eg. 50kg
(in total - 2kg of overall-mixture in ea bucket - we send 25 buckets)
44kg sugar (we pick/issue 3x20kg bags of sugar)
3.5kg salt (we pick/issue 1x10kg bags of salt)
2.5kg (premix1+premix2)

BlendPlant mix it, package it and send back [25 x 2kg]buckets
(this I'll call the micro-recipe for want of a better word) and leftovers.
(~16kg sugar + ~6.5kg salt - there are minor losses in the process).
Process takes a few days.
They charge a mixing fee and a filling fee - so in this case BlendCost=[50xfee/kg + 25xfee/fill]

B) Store/Lab receives back
* leftovers - which go back into inventory
* [25x2kg] buckets - which are transferred/sent to A)Shop


I need to know the cost of the micro-recipe as well as the macro-recipe.
If I haven't explained it properly...
(LabMix + cost of raw ingredients + 25 buckets + BlendCost)/25=cost per mixed bucket

What would be the "ideal" MRP/inventory issue/picklist flows?
Trent Murgatroyd
trent@murgatroyd.za.net
whatsapp/viber:+27718987802
pidgin/XMPP:t13@jabb.im/t14@jabb.im
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Best way to structure manufacturing/MRP flows [SOLVED] - by trentmurgatroyd - 05-05-2017, 11:54 AM

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