Cosmetics · MRP
MRP for cosmetics distributors
Today
A repack run is planned against a supplier lot that turns out to carry a customer-specific hold, and the plan has to be redone after the stock has already been picked.
Generic MRP plans quantity and timing. It doesn't know that a repack run draws from a lot with a document obligation, that a kit must combine components from approved suppliers only, or that some stock is reserved against a customer agreement.
With Worldover
Worldover MRP connects planning for repack, kitting and allocation to the lot, document and customer constraints already held on the product record.
Repack and kitting plans only draw on stock that's actually eligible, so plans don't have to be reworked after the fact.
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The problem
Why generic MRP failscosmetics distributor teams.
Planning ignores lot-level constraints
A repack plan is built against total stock quantity, without checking whether every lot in that total is actually eligible for it.
Kitting doesn't respect supplier approval
A kit combines components without checking that each supplier is currently approved and each lot is released.
Customer reservations are invisible to planning
Stock committed to a specific customer under contract is treated as free stock until someone allocates it twice.
A working day
A repack run
A customer orders a smaller pack size than the supplier's standard format.
Today: the repack is planned against available stock quantity, without checking lot-level eligibility until picking begins.
In Worldover: the plan only proposes lots that are released, documented and free of customer reservation.
The repack run confirms against real, eligible stock, with the correct documents flowing to the new pack.
The plan doesn't need to be reworked when picking starts.
How it runs
How MRP worksinside Worldover.
01
Plans draw on eligible stock only
Lot release status, document validity and customer reservation are checked before a lot is proposed for repack or kitting.
02
Kitting respects supplier approval
Components in a kit are checked against current supplier approval status, not assumed to be interchangeable.
03
Repack carries specification constraints forward
Shelf life, batch size and labelling rules from the original lot apply to the repacked output.
04
Allocation is visible across demand
Customer reservations, forecast orders and available stock are seen together, so double allocation doesn't happen.
What's in it
The detail behindMRP.
Manufacturing Execution System (MES)
Electronic batch records, dual signatures, QA release and full lot traceability.
Electronic batch records
Replace the paper batch record with records captured live across the manufacturing process.
Three-level order structure
Mixing, encapsulation and finished goods modelled as a linked order hierarchy, with material and lot flow between each level.
Dual-signature control
Performer and verifier electronic signatures against each recorded step, supporting 21 CFR Part 11 electronic signatures.
Multi-stage sampling and QA release
In-process sampling points and staged quality releases before a batch can progress.
Lot and batch traceability
Full lot traceability across every stage.
Incoming goods QA
Goods-in quality checks on receipt, with an internal lot ID assigned to every received material.
Demand Planning
Demand forecasting and sales velocity tracking feeding production planning.
Demand forecasting
Forecast from raw order data pulled through the Shopify and Fulfill APIs, with seasonality and trend analysis. Forecasts recalibrate as demand changes.
Sales velocity tracking
Sell-through by product, channel and region, replacing the manual demand work that drives stock-level and production inconsistency.
Production planning integration
AI-proposed manufacturing jobs from current inventory, incoming demand, safety stock and supplier lead times, surfaced for manual approval, then fed into production planning with automatic raw material ordering.
Production Planning
Production orders, scheduling, BOM explosion and AI-led capacity planning.
Production order management
Orders linked to formulations, BOMs and inventory, tracked through every manufacturing stage.
Scheduling and capacity planning
Schedule from a full resource map of machinery, labour, shifts and skill matrices, allocating machine slots, packing, filling and labour for maximum utilisation.
Labour costing and allocation
Cost labour against orders with configurable rate cards.
Bill of materials explosion
Explode BOMs from formulations to generate material requirements for each run.
PO management
Purchase orders linked to production requirements and supplier lead times.
AI-led automated production planning
Scheduling that optimises across machine throughput, staff capability, raw material lead times and job priorities, surfacing issues in real time with suggested fixes. Replaces the manual scheduling spreadsheet. Requires Inventory Management.
Inventory Management
Stock control, purchasing and supplier management in one place.
Inventory overview
A dashboard of stock levels for every item: raw materials, packaging and finished goods.
Stock and non-stock items
Separate items you always hold from items ordered for a specific job.
Request stock
Team members request stock against particular jobs.
PO management
End-to-end management of customer purchase orders.
Supplier order management
Supplier orders in one place, removing the email switching procurement relies on today.
Stock log audit
The audit trail underneath every stock calculation.
Warehouse Management
Locations, receiving, picking and dispatch with barcode scanning.
Location management
Zones, aisles, racks and bin locations with configurable hierarchies.
Receiving and putaway
Receive against purchase orders and assign putaway locations with barcode scanning.
Pick, pack and dispatch
Pick lists from production or customer orders, with pack confirmation and dispatch workflows.
Bin and location transfers
Stock movements between locations with a full audit trail.
Integration with Inventory
Natively linked to Inventory Management for real-time stock visibility.
The difference
Why the substance recordmakes the difference.
Planning in distribution is really planning around other people's constraints: their lots, their documents, their supply. Connecting the plan to the product record is what keeps a repack or kitting run realistic before it starts, not after.
Better together
What changes when MRPshares a record with the rest of your setup.
MRP + ERP
Confirmed plans convert into orders and allocations against the same stock and lot record.
Explore ERPMRP + QMS
Only lots with a current release status are proposed for repack or kitting.
Explore QMSMRP + PLM
Repack and kitting plans respect the specification constraints of the base product they draw from.
Explore PLMWillow
What teams actually askonce the record is in one place.
- Which lots are actually eligible for this repack run once documents and reservations are checked?
- Which kits depend on a component from a supplier whose approval has lapsed?
- How much stock is committed to customer agreements versus genuinely free for allocation?
Willow doesn't replace expert judgment. It removes the searching, re-keying and chasing between the systems that hold your answers.
Request a demo
We'll walk through your current workflow, then show the same workflow running on one record.
Research
Compared with the alternatives
If you're still building a shortlist, these break the market down side by side.
- ShortlistBest MRP software for cosmetics and chemicals in 2026Planning and materials tools ranked for substance-based manufacturing.Read it
- ComparisonWorldover vs NetSuiteWhere a generic cloud ERP stops on formulation and regulation.Read it
- ShortlistBest cosmetics ERPs in 2026How the main cosmetics ERPs compare on formulation, batch and regulatory depth.Read it