03PlanAI · Lumora Consumer ProductsDemo Data

Material Planning

Translate demand into material requirements — BOM explosion, MRP netting, pegging and shortage resolution.

Intelli AI Material Summary

Surfactant Base: opening 761.7 MT, confirmed receipts 1417.0 MT, 13-week requirement 2243.9 MT, safety stock 120.8 MT.

Projected shortage 86.3 MT — first shortage Week 5 (2 Nov). Apex Specialty Chemicals confirmed an 8-day delay on PO-48281; the delay affects production campaigns for liquid SKUs at Westport and Southbay.

Material requirement flow

Live calculation · Surfactant Base shown

Demand

29.0M u

Finished Goods Req.

28.7M u

Production Req.

28.2M u

BOM Explosion

100 BOMs · 3 levels

Gross Requirement

2243.9 MT SURF

On-Hand

761.7 MT

Scheduled Receipts

1417.0 MT

Safety Stock

120.8 MT

Net Requirement

186.0 MT

Purchase Recommendation

1 planned orders

MRP plan

Projected available balance by week · click a material for pegging

Material	Plant	Supplier	On Hand	Safety Stock	Incoming	Gross Req.	Net Req.	LT	MOQ	W1	W2	W3	W4	W5	W6	W7	W8	W9	W10	W11	W12	W13	Shortage	Risk	Recommended Action
PET360 · Packaging	Westport	Polyform Containers	1.3M	284K	4.0M	5.3M	48.7K	28d	243K	894K	507K	570K	183K	286K	747K	304K	783K	384K	879K	478K	970K	569K	—	Below SS	Release planned order
SURF · Raw Material	Westport	Apex Specialty Chemicals	761.7 MT	120.8 MT	1417.0 MT	2243.9 MT	20.5 MT	42d	104.0 MT	597.4 MT	431.4 MT	263.9 MT	96.2 MT	-86.3 MT	93.6 MT	288.4 MT	217.1 MT	427.2 MT	256.5 MT	465.6 MT	295.3 MT	125.1 MT	W5	Shortage	Expedite / transfer
SLES · Raw Material	Westport	Meridian Surfactants	331.9 MT	33.5 MT	109.0 MT	623.0 MT	16.1 MT	35d	29.0 MT	286.0 MT	239.9 MT	193.4 MT	146.8 MT	97.6 MT	157.3 MT	107.3 MT	59.4 MT	38.4 MT	34.2 MT	33.9 MT	33.9 MT	33.8 MT	—	Healthy	None
CAPB · Raw Material	Westport	Corvane Chemicals	139.2 MT	9.6 MT	0.0 MT	250.7 MT	8.7 MT	35d	12.0 MT	120.7 MT	102.1 MT	83.4 MT	64.7 MT	44.3 MT	23.9 MT	15.2 MT	9.7 MT	9.7 MT	10.6 MT	10.5 MT	10.5 MT	10.5 MT	—	Healthy	None
CPOLY · Raw Material	Westport	NovaPolymers	53.6 MT	4.4 MT	18.0 MT	82.1 MT	1.0 MT	49d	4.0 MT	47.7 MT	41.6 MT	35.6 MT	29.5 MT	22.7 MT	15.9 MT	8.9 MT	20.4 MT	14.3 MT	8.1 MT	5.9 MT	4.7 MT	4.5 MT	—	Healthy	None
PRES · Raw Material	Westport	Ridgeway Preservatives	22.1 MT	1.9 MT	10.0 MT	49.8 MT	1.2 MT	28d	2.0 MT	18.4 MT	14.7 MT	11.0 MT	7.2 MT	13.3 MT	9.3 MT	5.3 MT	3.5 MT	2.6 MT	2.6 MT	2.8 MT	2.1 MT	2.3 MT	—	Healthy	None
COLOR · Raw Material	Westport	Cobalt Pigments	3.5 MT	0.3 MT	3.0 MT	11.5 MT	0.2 MT	21d	1.0 MT	2.6 MT	1.7 MT	0.9 MT	3.0 MT	2.1 MT	1.2 MT	1.3 MT	0.4 MT	0.5 MT	0.6 MT	0.7 MT	0.8 MT	0.9 MT	—	Healthy	None
GLYC · Raw Material	Northgate	Pinecrest Glycerin	35.0 MT	3.7 MT	17.0 MT	95.0 MT	3.3 MT	21d	4.0 MT	27.8 MT	20.7 MT	13.4 MT	23.1 MT	15.7 MT	8.4 MT	5.1 MT	3.7 MT	4.3 MT	4.0 MT	4.6 MT	4.3 MT	4.0 MT	—	Healthy	None
NOODLE · Raw Material	Northgate	Silvergate Oleochem	836.6 MT	91.8 MT	350.0 MT	1705.8 MT	46.8 MT	35d	79.0 MT	706.6 MT	576.8 MT	446.8 MT	316.6 MT	184.5 MT	403.1 MT	271.4 MT	139.4 MT	92.1 MT	92.5 MT	92.7 MT	92.4 MT	91.9 MT	—	Healthy	None
FATTY · Raw Material	Northgate	Silvergate Oleochem	43.3 MT	3.5 MT	0.0 MT	89.8 MT	3.3 MT	28d	4.0 MT	36.5 MT	29.6 MT	22.8 MT	16.0 MT	9.0 MT	6.1 MT	4.1 MT	4.2 MT	4.2 MT	4.3 MT	4.4 MT	4.4 MT	3.5 MT	—	Healthy	None
TIO2 · Raw Material	Northgate	Lumex Minerals	4.9 MT	0.3 MT	0.0 MT	7.9 MT	0.1 MT	42d	1.0 MT	4.3 MT	3.7 MT	3.1 MT	2.5 MT	1.9 MT	1.3 MT	0.7 MT	1.1 MT	0.5 MT	0.8 MT	1.2 MT	0.6 MT	1.0 MT	—	Healthy	None
EMUL · Raw Material	Northgate	Emulsia Ingredients	15.8 MT	1.5 MT	0.0 MT	27.9 MT	0.8 MT	35d	1.0 MT	13.7 MT	11.5 MT	9.4 MT	7.3 MT	5.1 MT	3.0 MT	1.8 MT	1.7 MT	1.5 MT	2.3 MT	2.2 MT	2.1 MT	1.9 MT	—	Healthy	None
ACTIVE · Raw Material	Northgate	Terraform Bio	3.7 MT	0.3 MT	2.0 MT	5.2 MT	0.0 MT	56d	1.0 MT	3.3 MT	2.9 MT	2.5 MT	2.1 MT	1.7 MT	1.3 MT	0.9 MT	0.5 MT	2.1 MT	1.7 MT	1.3 MT	1.0 MT	0.6 MT	—	Excess	Defer receipts
FRAG-silk · Raw Material	Westport	Halden Fragrance House	10.3 MT	0.9 MT	4.0 MT	16.4 MT	0.2 MT	42d	1.0 MT	9.1 MT	8.0 MT	6.8 MT	5.6 MT	4.2 MT	2.8 MT	5.4 MT	4.0 MT	2.8 MT	1.6 MT	1.3 MT	1.1 MT	0.9 MT	—	Healthy	None
FRAG-fresh · Raw Material	Westport	Aurelia Aromatics	9.6 MT	0.8 MT	4.0 MT	15.5 MT	0.1 MT	42d	1.0 MT	8.4 MT	7.3 MT	6.1 MT	4.9 MT	3.7 MT	2.4 MT	5.2 MT	4.0 MT	2.8 MT	1.6 MT	1.4 MT	1.2 MT	1.1 MT	—	Healthy	None
FRAG-repair · Raw Material	Westport	Halden Fragrance House	5.2 MT	0.5 MT	2.0 MT	8.4 MT	0.0 MT	42d	1.0 MT	4.6 MT	3.9 MT	3.3 MT	2.6 MT	2.0 MT	1.3 MT	2.6 MT	2.0 MT	1.3 MT	0.7 MT	1.0 MT	1.4 MT	0.8 MT	—	Healthy	None
FRAG-smooth · Raw Material	Westport	Aurelia Aromatics	3.9 MT	0.4 MT	2.0 MT	7.5 MT	0.0 MT	42d	1.0 MT	3.4 MT	2.8 MT	2.3 MT	1.7 MT	1.1 MT	2.5 MT	1.9 MT	1.3 MT	0.7 MT	1.2 MT	0.6 MT	1.0 MT	0.5 MT	—	Healthy	None
FRAG-pgbeauty · Raw Material	Northgate	Halden Fragrance House	6.7 MT	0.4 MT	3.0 MT	11.6 MT	0.1 MT	42d	1.0 MT	5.8 MT	4.9 MT	4.1 MT	3.2 MT	2.3 MT	1.4 MT	3.5 MT	2.6 MT	1.7 MT	0.8 MT	0.9 MT	1.0 MT	1.1 MT	—	Healthy	None
FRAG-pgfresh · Raw Material	Northgate	Aurelia Aromatics	4.7 MT	0.3 MT	2.0 MT	8.4 MT	0.0 MT	42d	1.0 MT	4.1 MT	3.4 MT	2.8 MT	2.2 MT	1.5 MT	0.9 MT	2.2 MT	1.6 MT	0.9 MT	1.3 MT	0.6 MT	0.9 MT	1.3 MT	—	Healthy	None
FRAG-pgsens · Raw Material	Northgate	Halden Fragrance House	2.2 MT	0.2 MT	1.0 MT	4.0 MT	0.0 MT	42d	1.0 MT	1.9 MT	1.6 MT	1.3 MT	1.0 MT	0.7 MT	0.4 MT	1.1 MT	0.8 MT	0.5 MT	0.2 MT	0.9 MT	0.6 MT	0.3 MT	—	Healthy	None

111 materials · page 1/6

Shortage explainer — Surfactant Base

Opening inventory

761.7 MT

Confirmed receipts

1417.0 MT

13-week requirement

2243.9 MT

Safety stock

120.8 MT

Projected shortage

86.3 MT

First shortage

Week 5

PO-48281 (277 MT, Apex Specialty Chemicals) moved 8 days → receipt shifts from W5 to W6, leaving W5 uncovered inside the 6-week lead-time fence.

Material action options

Each applies to the live plan and recalculates

Option	Recovered	Cost	Lead time	Service	Risk
Expedite existing PO	8.0 MT	$78.4K	10 days	+2.1 pts	Medium
Transfer material from Northgate	11.0 MT	$28.6K	4 days	+2.6 pts	Low
Use approved alternate supplier	12.0 MT	$41.0K	28 days	+0.8 pts	Medium
Reschedule production	—	$26.0K	1 week	+1.1 pts	Low
Reduce safety stock temporarily	24.2 MT	$0	Immediate	+0.4 pts	High
Use approved substitute material	9.0 MT	$12.6K	14 days	+1.9 pts	QA release
Prioritize high-service SKUs	—	$0	Immediate	Protects strategic	Low

Material substitute logic

Alternate material master — never auto-applied

Primary

Surfactant Base A

Approved substitute

Surfactant Base B

Conversion factor

1.02

Quality approval

Approved

Applicable SKUs

Cost difference

+3.4%

Safety stock intelligence

Current vs recommended (days of cover)

Material	Current	Recommended	Demand CV	LT CV	Target	Gap
180ml PET Bottle	12d	9d	0.08	0.10	98%	3d excess
360ml PET Bottle	10d	8d	0.10	0.15	98%	2d excess
Surfactant Base	13d	12d	0.12	0.20	98%	1d excess
Bottle Cap 24mm	8d	8d	0.14	0.10	98%	OK
250ml HDPE Bottle	11d	12d	0.16	0.15	98%	1d short
Label — Lumora Silk Shampoo	14d	17d	0.18	0.20	95%	3d short
Soap Noodles	9d	6d	0.20	0.10	98%	3d excess
Soap Wrapper — PureGlow Fresh	12d	10d	0.22	0.15	98%	2d excess

Material cover heatmap

Top 18 materials by risk

HealthyBelow safety stockShortage riskStockoutExcess

Material	W1	W2	W3	W4	W5	W6	W7	W8	W9	W10	W11	W12	W13
360ml PET Bottle	2.2	1.3	1.4	0.5	0.7	1.8	0.7	1.9	0.9	2.2	1.2	2.4	1.4
Surfactant Base	3.5	2.5	1.5	0.6	0.0	0.5	1.7	1.3	2.5	1.5	2.7	1.7	0.7
Sodium Laureth Sulfate	6.0	5.0	4.0	3.1	2.0	3.3	2.2	1.2	0.8	0.7	0.7	0.7	0.7
Cocamidopropyl Betaine	6.3	5.3	4.3	3.4	2.3	1.2	0.8	0.5	0.5	0.5	0.5	0.5	0.5
Conditioning Polymer	7.5	6.6	5.6	4.7	3.6	2.5	1.4	3.2	2.3	1.3	0.9	0.7	0.7
Preservative	4.8	3.8	2.9	1.9	3.5	2.4	1.4	0.9	0.7	0.7	0.7	0.5	0.6
Colorant	2.9	2.0	1.0	3.4	2.4	1.3	1.4	0.4	0.5	0.6	0.8	0.9	1.1
Glycerin	3.8	2.8	1.8	3.2	2.2	1.2	0.7	0.5	0.6	0.5	0.6	0.6	0.5
Soap Noodles	5.4	4.4	3.4	2.4	1.4	3.1	2.1	1.1	0.7	0.7	0.7	0.7	0.7
Fatty Acid Blend	5.3	4.3	3.3	2.3	1.3	0.9	0.6	0.6	0.6	0.6	0.6	0.6	0.5
Titanium Dioxide	7.1	6.1	5.1	4.1	3.1	2.1	1.1	1.8	0.7	1.4	2.0	1.0	1.6
Lotion Emulsifier	6.4	5.4	4.4	3.4	2.4	1.4	0.8	0.8	0.7	1.1	1.0	1.0	0.9
Active Ingredient	8.4	7.4	6.4	5.4	4.4	3.4	2.4	1.4	5.4	4.4	3.4	2.4	1.4
Fragrance Compound — Lumora Silk	7.2	6.3	5.4	4.5	3.3	2.2	4.3	3.2	2.2	1.2	1.1	0.9	0.7
Fragrance Compound — Lumora Fresh	7.1	6.1	5.1	4.1	3.1	2.0	4.3	3.4	2.4	1.4	1.2	1.0	0.9
Fragrance Compound — Lumora Repair	7.0	6.0	5.1	4.1	3.0	2.0	4.0	3.0	2.0	1.0	1.6	2.2	1.2
Fragrance Compound — Lumora Smooth	5.9	4.9	3.9	3.0	1.9	4.3	3.3	2.3	1.3	2.1	1.1	1.8	0.8
Fragrance Compound — PureGlow Beauty	6.5	5.6	4.6	3.6	2.6	1.6	3.9	2.9	1.9	0.9	1.0	1.2	1.3