🏭 FactoryOS — MRP Engine Pro

A Professional Material Requirements Planning System Built in Excel

🎯 Product Title

FactoryOS MRP Engine Pro — Multi-Level BOM Explosion and Material Planning System

💡 Tagline

A real APICS-grade MRP engine that tells you exactly what to buy, what to make, and when to act — without the cost and complexity of a full ERP system.

🔥 Why This Template Stands Out

Most Excel files marketed as “MRP systems” are little more than inventory trackers with polished formatting.

FactoryOS MRP Engine Pro is different. It is built on genuine APICS / CPIM methodology — the same planning logic used by systems such as SAP, Oracle, and Odoo — but delivered in a format that is transparent, auditable, and fully driven by formulas.

There are no macros, no add-ins, and no black-box logic.
Just real MRP mechanics you can trust, understand, and confidently explain to management.

⚙️ Core Engine Capabilities

1. True Multi-Level BOM Explosion

The system explodes demand from finished goods down through sub-assemblies, components, and raw materials.

It supports unlimited BOM levels with automatic low-level coding, allowing the planning logic to flow correctly across complex product structures.

It also handles:

• Scrap factors

• Yield percentages

• Component quantity multipliers

In addition, it provides clear parent-child dependency mapping with visual indentation for easier navigation and review.

2. Time-Phased Weekly Planning Across a 12-Week Horizon

For every item, the engine calculates a complete weekly planning picture over a 12-week horizon.

This includes:

• Gross Requirements derived from independent demand and parent orders

• Scheduled Receipts from open purchase orders and work orders

• Projected On-Hand Balance

• Net Requirements after considering available stock and safety stock

• Planned Order Receipts

• Planned Order Releases offset by lead time

This gives planners a structured and forward-looking view of supply and demand across the entire planning period.

3. Lead-Time Offsetting and Lot-Sizing Logic

The template supports multiple replenishment policies so planning recommendations align with real operational rules.

Supported logic includes:

• Lot-for-Lot (L4L): order exactly the amount required

• Fixed Order Quantity (FOQ): follow supplier minimums or standard order quantities

• Min/Max policies: maintain replenishment within defined boundaries

The system automatically back-schedules release dates based on lead times, helping users know exactly when orders must be launched.

4. Smart Traffic-Light Alert System

To help users identify priorities quickly, the engine includes an intuitive visual alert system.

It highlights:

• Red alerts for projected shortages or stock-outs by week

• Yellow alerts for items requiring action this week

• Green status for items fully covered by inventory and scheduled receipts

It also includes “Release Now” flags so urgent actions can be identified and executed immediately.

5. Separate Buy and Make Action Plans

The output is divided into two practical execution plans:

Buy Plan
This provides consolidated purchasing recommendations by vendor, item, week, and value, making it easier for procurement teams to act quickly.

Make Plan
This provides production order suggestions by week and quantity, helping planners align manufacturing activity with material availability and demand.

The workbook also includes:

• A procurement calendar view for purchasing teams

• A production calendar view for shop-floor scheduling

6. Executive MRP Dashboard

The template includes a management dashboard that summarizes key planning and supply chain metrics in a clear, decision-ready format.

Dashboard insights include:

• Total inventory exposure in value terms

• Weekly procurement spend forecast

• Top 10 critical shortages

• BOM coverage percentage by finished good

• Vendor concentration analysis

• Make-versus-buy ratio

This helps management understand risk, cost, and execution priorities at a glance.

📋 What’s Inside the Workbook

The workbook includes a complete set of structured sheets covering the full MRP process:

• README & Quick Start
  A step-by-step guide to setting up and using the file

• Item Master
  Stores SKU, item type, unit of measure, lead time, lot size, and safety stock

• BOM (Bill of Materials)
  Defines the parent-child structure, required quantities, and scrap assumptions

• Inventory On-Hand
  Captures current stock balances by item and location

• Scheduled Receipts
  Tracks open purchase orders and work orders with due dates

• MPS (Master Production Schedule)
  Contains independent demand by week

• MRP Calculation Engine
  The formula-driven time-phased planning core

• Buy Plan
  Converts planning output into supplier-ready purchase recommendations

• Make Plan
  Converts planning output into production release recommendations

• Shortage Report
  Highlights critical shortages with root-cause visibility

• Executive Dashboard
  Presents KPIs, charts, and spend forecasts

• Settings & Parameters
  Controls calendar settings, currency, and planning horizon assumptions

👥 Who This Is For

FactoryOS MRP Engine Pro is ideal for:

• Production planners managing weekly manufacturing schedules

• Materials managers dealing with recurring shortages

• Supply chain analysts who need transparent and traceable calculations

• Operations managers in SMEs that do not yet have a full ERP system

• Manufacturing consultants delivering planning tools to clients

• APICS / CPIM students learning real-world MRP logic

• Plant managers moving from reactive spreadsheets to structured planning

💼 Expected Business Impact

Using this system can lead to meaningful improvements in planning performance and operational control.

Typical outcomes may include:

• A reduction in stock-outs by approximately 40% to 60%

• A reduction in inventory carrying costs by approximately 15% to 25%

• Up to 50% less planner time spent on reactive firefighting

• On-time delivery improvement of roughly 10% to 20%

• Planning visibility improved from days of manual work to minutes

🎁 What You Receive

With FactoryOS MRP Engine Pro, you get:

• A fully unlocked Excel workbook in .xlsx format

• A sample BOM dataset including 3 finished goods, 4 BOM levels, and more than 25 items

• A step-by-step PDF user guide

• A 15-minute video walkthrough

• Fully editable and auditable formulas

• Compatibility with Excel 2016, 2019, 2021, 365, and Excel for Mac

• Lifetime updates

• Email support

🛡️ Built on Proven Planning Standards

This template is designed in alignment with the APICS / ASCM CPIM body of knowledge and follows MRP I logic as defined by Orlicky’s MRP framework.

These are the same core planning principles that power many of the world’s leading ERP systems.

🚀 Stop Planning on Gut Feel. Start Planning on Logic.

FactoryOS MRP Engine Pro transforms your spreadsheet from a passive tracker into an active planning engine that tells you what to do today, this week, and across the next 12 weeks.

If you can enter your BOM and inventory, the engine does the rest.

📩 Get FactoryOS MRP Engine Pro Today

Bring real APICS-grade MRP logic into your factory — directly in Excel.