Shortage Report

The Inventory Shortage Report (or Allocation Shortage Report) is the primary source for material requirements planning for one or more builds in the allocation stage. It is composed of a part-by-part detail of quantity requirements to satisfy the builds in progress and is most often used to inform quoting and purchasing activities.

When you maintain component inventory levels within Aligni, you have the capability to compute a “shortlist” for an assembly build. A shortlist is a list of individual material requirements to complete the assembly of a partlist.

There are two ways to generate a shortage report. Both are links available at the top right of the Build Manager which is shown on the Inventory Dashboard as well as your Aligni home page.

Allocation Shortage Report

ShortageReport-AllocationsUnlike the quick shortage report, an allocation shortage report does not allow you to manually enter assemblies. Instead, the allocation shortage report relies on existing builds you have setup and are presently in the allocation stage. Since the allocation shortage report uses builds that are stored in your database, the same report is available at any time and by any user. The reporting only changes when inventory changes or the builds in allocation change.

The assemblies list for an allocation shortage report includes important details about each build such as the quantity, the part being built, the part list version, and whether “drill-down” was selected when the build was initiated. To the left of each build in the list is a small circle representing the shortage status:

  • Green means that there are no material shortages for the build.
  • Yellow means that there are shortages, but a partial build could be run.
  • Red means that shortages prevent any of the build quantity from being built.

Check the option Consider Parts on Order to remove material shortages from the list that are satisfied with current outstanding purchase orders. This can focus your attention to shortages that still need to be handled.

Reading the Report

Build # Part Number Quantity

The inventory shortage list contains a lot of information which can be a little overwhelming at first. The screenshot below points out the details for reading the list based on the requirements for the builds in the table on the right.

Along the left column are all of the components required to complete the builds presently in allocation. The next column (Total Required) shows the number of each item required. You can click on the information icon here to get a brief material summary of this item.

The remaining columns can be read, from left to right, as a sort of simulation of time and how your inventory, builds, and purchases will play out:

  • Starting at the left is the Total on Hand column which indicates your present inventory available for builds.
  • Each build is then ordered chronologically left to right.
  • Builds consume inventory and indicate shortages by coloring the cell appropriately (see the legend below).
  • Purchases refill inventory and are indicated by the small encircled arrows.
  • Safety stock indicators (if selected) are shown as horizontal lines at the bottom and top of each cell to indicate if you are below or above your target inventory level in that period.
  • At the far right is the Still Short column indicating any unresolved material requirements at “infinity”.

Material Requirement Legend

  1. The Overstock Indicator is shown in a period where the forecast inventory quantity is above the established inventory maximum for the item.
  2. The quantity of an item allocated to the build is shown as the Quantity Required.
  3. The Safety Stock Indicator is shown in a period where the forecast inventory quantity is below the established inventory minimum for the item.
  4. When a build only has partial material requirements, the buildable quantity is indicated by Nmax.
  5. The blue encircled arrow at the left of a cell indicates that there is arriving inventory on a purchase due before the build date.
  6. The red encircled arrow at the right of a cell indicates that there is inventory on order on a purchase due sometime after the build date.

Purchases and Promise Dates

Material requirements planning works best when there is a well-established timeline for the execution of events. This timeline relies on your build expected reserve dates to determine when a build will be performed as well as the promise dates for items arriving on purchase orders from suppliers.

When a promise date is unavailable for an item, Aligni places the arrival of that inventory just before the Still Short column. This can help you find those purchases and update the promise dates manually or ask your suppliers to do so.

Quick Shortage Report

ShortageReport-QuickA quick shortage report can be created at any time by simply adding assemblies and corresponding build quantities to the report list. Aligni will compute shortages based only on these assemblies, the present inventory at the inventory locations you select, and (optionally) outstanding purchases.

After you’ve added the assembly part numbers, you can adjust quantities, rearrange the build order by drag / drop, and remove assemblies from the list.

The Quick Shortage Report considers the relative order of the assemblies but does not consider the timing of incoming inventory. This detail is only available in the full build-based Allocation Shortage Report.

The list of assemblies you enter for a Quick Shortage Report is private to your account and not visible to other users.