The short answer
To know whether you have enough material for a production job, separate four quantities: stock that is usable now, stock received but still waiting for quality inspection, material open on approved purchase orders with its due date, and the quantity the job requires. A single stock balance mixes these together and gives the wrong answer.
Why a stock balance is not an answer
"We have 860 kg" sounds like enough for a 500 kg job. But if 150 kg of that is waiting at quality and 400 kg is on a purchase order that has not arrived, only 310 kg can actually be issued today. The job is short by 190 kg, and the shortage is discovered on the shop floor instead of at planning.
The four quantities to separate
| Quantity | Source record | Example | Usable now? |
|---|---|---|---|
| Available in stores | Stock balance with status available | 310 kg | Yes |
| Received, waiting for QA | GRN line pending inspection | 150 kg | Not yet |
| Open on purchase order | Open delivery on an approved PO, due 14 Oct | 400 kg | Not yet |
| Required by the job | Production requirement | 500 kg | — |
From this table: 310 kg is usable today, 190 kg is still to cover. If the 150 kg at QA is accepted, 40 kg remains to cover, and the next delivery of 400 kg is due on 14 October.
Questions to ask before releasing a job
- Is the usable quantity enough on its own?
- If not, is the shortfall covered by material already at QA — and when will QA finish?
- If not, is there an open purchase order, and is its due date before the job needs to start?
- If not, does a new requisition need to be raised now?
- Are any of the available batches reserved for another job?
What your records need for this to work
- Stock recorded by batch and status, not just by material
- Receipts kept separate from quality-accepted stock
- Purchase orders with scheduled delivery dates, not just an order date
- A production requirement per job, ideally from a bill of materials
Where mosaicOne stands
mosaicOne keeps the first three quantities as separate records today: inventory balances by batch and status, GRN lines awaiting inspection, and open delivery batches on approved purchase orders. Checking them automatically against a production order — along with bills of materials and material issue — is part of the production module currently in development.
Key takeaways
- Never plan from a single stock balance.
- Separate usable, waiting-for-QA and on-order quantities.
- Check PO due dates against the job start date.
- Raise requisitions at planning time, not when the shop floor runs short.