Material
How a breakage on the floor turns into a supplier order without anyone keeping a list — and why this is the part that usually gets lost.
Two things belong together here that many plants keep apart: what lies in stock and what has to be re-ordered from the supplier. Kept apart, in practice, means both end up on the same scrap of paper, and the paper eventually disappears.
What triggers a re-order is rarely an inventory count. It is a breakage in production, a special request, or a unit that has to be remade. The information for it appears exactly where that happens.
How it connects
Five places where a note would otherwise be lying around.
What is on hand sits in the system, not in the head of the stores clerk. Orders served from stock can be picked line by line.
When something breaks in production, the reason is recorded per component — glass and film separately, because they have neither the same cause nor the same supplier.
Sheets flagged defective land in their own re-order view. What has to be ordered from the supplier therefore comes out of production rather than out of a follow-up question.
An order with a supplier is a record with its own state — not an email in the sent folder whose answer somebody keeps in their head.
When material arrives it is marked on the order and the people responsible are notified. The floor finds out without asking.
Breakage is unpleasant, and unpleasant things get documented when documenting is easy. If recording it is a separate task at the end of the day, it happens incompletely — and what is then missing is exactly the basis you would later need to see whether the cause is a lot, a step, or a supplier.
Record the reason where the breakage happens and that basis builds itself. A few months in, it answers a question nobody could answer before.
Common questions
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