Cosmetics · MRP
MRP for cosmetics distributors
MRP for cosmetics distributors. Repacking, kitting and stock allocation planning respect the lot, document and customer constraints on the products you distribute.
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.
What's in it
What MRPdoes inside Worldover.
The operational outcomes come first. Open any area to inspect the underlying controls, records and technical detail.
Standards and regimes
01Manufacturing 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.
02Demand PlanningDemand 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.
03Production PlanningProduction 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.
04Inventory ManagementStock 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.
05Warehouse ManagementLocations, 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.
One workflow, end to end
A repack run
The difference isn't another isolated tool. It's the same work running from one live record.
Where work breaks
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.
- 01
A customer orders a smaller pack size than the supplier's standard format.
- 02
Today: the repack is planned against available stock quantity, without checking lot-level eligibility until picking begins.
- 03
In Worldover: the plan only proposes lots that are released, documented and free of customer reservation.
- 04
The repack run confirms against real, eligible stock, with the correct documents flowing to the new pack.
- 05
The plan doesn't need to be reworked when picking starts.
With Worldover
- 1
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.
- 2
Kitting respects supplier approval
Components in a kit are checked against current supplier approval status, not assumed to be interchangeable.
- 3
Repack carries specification constraints forward
Shelf life, batch size and labelling rules from the original lot apply to the repacked output.
- 4
Allocation is visible across demand
Customer reservations, forecast orders and available stock are seen together, so double allocation doesn't happen.
Connected inside Worldover
One product workflow.Every consequence connected.
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.
Willow
Useful AI starts with live operational context.
Scoped permissions, human approval for anything material and a full audit trail of every action.
- 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?
Buyer confidence
A specialist system, without a specialist-system rollout.
Worldover combines detailed operational control with a practical route to a live first phase.
- 50+
- Enterprise customers across cosmetics, chemicals and supplements
- 4 to 7
- Point systems typically retired, most within 6 months of go-live
- 12 to 16 weeks
- To a live Phase 1, not a multi-year programme
- 1 record
- Per substance, everywhere it appears
See it on your operation
Book a 30-minute slot
Give us the essentials, then choose a 30-minute slot directly in the right person’s calendar. We’ll use your workflow, products and documents, not a generic slide deck.