Supplements · MRP
MRP for supplement manufacturers
Today
The plan says you have enough active for the run. The plan didn't know about overage, yield loss or the lot that expires first.
Generic MRP nets demand against item quantities. It has no concept of assay-adjusted requirements, overage, blend yield or shelf-life sequencing, so shortages appear on the day of blending.
With Worldover
Worldover MRP connects the released formulation, overage rules, yield history, lot expiry, supplier lead times and line capacity into one plan.
Material calls and blend sizes reflect what production will actually consume, so runs start when they're planned to.
USED BY 250+ INDUSTRY LEADERS
The problem
Why generic MRP failssupplements manufacturer teams.
Requirements ignore potency
A 200mg declared dose isn't a 200mg material call once assay and overage are applied, so nets are wrong before anything is ordered.
Yield is a guess
Loss on blending, compression and coating isn't captured against the product, so the same shortfall repeats every campaign.
Expiry isn't sequenced
Lot expiry sits in the warehouse system, so short-dated material is used late or written off.
A working day
Planning next month's campaigns
Three customers confirm orders that share two actives and one bottling line.
Today: the planner rebuilds requirements in a spreadsheet, then adds a margin for overage from memory.
In Worldover: requirements are calculated from the released formulation with assay, overage and historical yield applied.
Lots are proposed in expiry order, and short-dated material is allocated where shelf life allows.
Line and packing capacity are checked in the same view, so a promised date is a date you can hold.
How it runs
How MRP worksinside Worldover.
01
Demand meets the real formulation
Requirements come from the released version, including overage and excipient adjustments.
02
Stock is netted by lot
Availability accounts for quality status, allocations and expiry, not just a quantity on hand.
03
Capacity is part of the answer
Blending, encapsulation, tableting and packing capacity are checked alongside materials.
04
Shortages surface early
Lead-time gaps and short-dated lots appear while there's still time to act on them.
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 off the substance record means the same active is one requirement across every product that uses it, adjusted for assay and overage, so purchasing consolidates properly rather than ordering per product code.
Better together
What changes when MRPshares a record with the rest of your setup.
Willow
What teams actually askonce the record is in one place.
- What do we need to buy for next month's campaigns once overage is applied?
- Which planned batches are at risk from lot expiry?
- Can we bring this customer's run forward without breaking another order?
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.
- GuideWhy generic ERPs fail substance businessesThe data model problem behind most failed implementations.Read it
- ComparisonWorldover vs spreadsheets and shared drivesThe real cost of the stack most teams are still running.Read it
- ComparisonWorldover vs an in-house ERP and PLM stackBuild versus buy, with maintenance cost included.Read it