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How to prevent material shortages
Most shortages are visible days in advance. This is a simple routine to see them in time.
Start with the materials that can stop a line
You do not need to track every item daily. List the 15 to 20 materials that would stop production if they ran out. Include packing material and bought-out parts, not only raw material.
Know usable stock, not total stock
- Subtract rejected and hold stock
- Subtract stock reserved for confirmed orders
- Count the critical items weekly
Check days of cover every morning
Days of cover is usable stock divided by average daily use. If it is shorter than the supplier lead time and nothing is on order, you are already late.
Get supplier dates in writing
Ask for every delivery date on WhatsApp or email and copy it into one tracker that stores and planning can see.
Tell planning the same day
A shortage you know about on Monday can be planned around. One you find on Thursday stops a line.