[Cosmetics Manufacturing] ORCA MES & MRP Material Shortage Case Study
ORCA MES & MRP Help Check Material Shortages Before Production
This cosmetics manufacturing case study shows how food and cosmetics plants often discovered shortages late because formula ingredients and packaging materials were checked separately.
When production plans changed, teams had to confirm which materials and quantities were needed again.
ORCA MES & MRP work as a manufacturing MES and production management system by showing current quantities and shortages for materials needed for production in one view.
- Product-level production plans and material status make the checking scope clear.
- Required and shortage quantities help narrow the items that need adjustment.
- Shared information on PC, tablet, and mobile reduces remote checking effort.
Customer Case Problem
This manufacturer produced essences, creams, and set products in high-mix, low-volume batches.
Main and auxiliary material requirements differed by formula version.
After semi-finished products were subdivided, containers, unit cartons, and labels varied by SKU.
Raw material LOTs and packaging material receipt status had to be checked separately.
When production plans were adjusted, shortage materials appeared right before work began.
The plant manager needed a standard view for available production quantity and shortage materials.
What ORCA MES & MRP Solved and the Work Scope
The plant organized production items and input materials as master data.
BOM material composition and requirements became the standard for material needs in production plans.
Application Process
- Ingredient, container, and label requirements were linked to BOMs for products and semi-finished products.
- Material receipt and issue records were registered to check current warehouse quantities.
- Production Status Inquiry showed material status and shipment status together by plan.
Work Benefits for the Customer
- Required materials and standard quantities by product are used before production.
- Material lists needed for production plans are linked with BOM material composition.
- Current material quantities and available production quantities are checked together.
- The list shows statuses such as before production, in production, completed, and stopped.
- When materials are short, details show required quantity and shortage quantity.
When production progress and product shipment records are current, the calculation basis becomes more accurate.
Work Comparison: Before and After ORCA
| Work Situation | Before | After ORCA |
|---|---|---|
| Pre-production material check | Formula ingredients and packaging materials were compared separately to judge shortages. | Material status and available production quantity are viewed together by production plan. |
| Shortage material check | Which materials were short, and by how much, was known right before work. | Required quantity and shortage quantity are reviewed in detail when a shortage appears. |
| Production progress check | Production progress and shipment status were checked in different materials. | Production status and product issue status are checked in the same list. |
| Shop-floor sharing | The plant manager and shop-floor staff often viewed different materials. | The same screen is viewed remotely on PC, tablet, and mobile. |
Frequently Asked Questions
- What setup is needed in ORCA MES & MRP to view available production quantity and shortage materials?
- Items, item classifications, material requirement standards, material inventory, and production plans must be registered first.
- How are shortage materials reviewed?
- Set the top filters and search. If the status shows a shortage, review required and shortage quantities in the details.
- Does the Production Status Inquiry screen change inventory or production plans?
- This screen is view-only. It does not save or change production plans, inventory, or shipment information.