Katana Manufacturing Order Ingredients Not Available: How to Resolve
Katana manufacturing order ingredients not available
Also searched as
- Katana ingredient shortage manufacturing order
- Katana can't start manufacturing order not enough stock
- Katana ingredients expected not in stock
- Katana make to order shortage purchase order
Short answer
A Katana manufacturing order flags an ingredient as not available when free stock at the order's location is less than the recipe quantity and no incoming purchase or manufacturing order covers the gap. Resolve it by checking the ingredient's stock by location, creating or expediting a purchase order, fixing a wrong location or recipe, or correcting stock with an adjustment or stocktake.
Applies to: Katana Cloud Inventory manufacturing orders and make-to-order or make-to-stock workflows. Exact status labels may differ slightly between app versions.
How to clear an ingredient shortage
- 1Open the manufacturing order and read the ingredient rows. Note which are in stock, expected (covered by an incoming order) and not available.
- 2Open the short ingredient and check stock by location. A common cause is that stock exists, but in another location than the order's production location.
- 3Check what is already committed. Stock allocated to other manufacturing orders or sales orders is not free for this one.
- 4If the item is genuinely short, create a purchase order from the sales or manufacturing order shortage view, or from the item, and set a realistic expected arrival date.
- 5If the item is made in-house, make sure it has its own recipe and create a manufacturing order for the sub-assembly.
- 6If the physical stock exists but the system says zero, fix it with a stock adjustment or a stocktake, and find out why receipts were not recorded.
- 7Check the recipe quantity and unit of measure. A recipe in the wrong unit can make the demand look far larger than reality.
- 8Re-open the order and confirm the status moved to in stock or expected before scheduling production.
How Katana decides availability
Katana compares the recipe demand of each manufacturing order with free inventory at the production location, then looks at open supply: purchase orders with expected dates and other manufacturing orders that will produce the item. Stock that covers the need is shown as in stock, supply that is coming is shown as expected, and anything left over is not available.
Because allocation follows order priority and dates, adding a new urgent order can quietly flip an older order from in stock to short. That surprises planners who assume the stock was reserved forever. Treat the status as a live calculation, not a promise.
The usual root causes
Wrong location is the top cause: raw material received into a general warehouse while the order produces at a workshop location. A transfer or a corrected receipt location fixes it in minutes. Second is unrecorded receipts: goods arrived but the purchase order was never marked received, so the system believes the shelf is empty.
Third is recipe error: an extra ingredient left on a recipe after a design change, a wrong quantity per unit, or a batch recipe built for ten units used as if it were for one. Fourth is real shortage with no purchase order, which is the system working as designed and telling you to buy.
Choosing between purchase, make and adjust
Buy when the item is a purchased part and lead time fits the order date. Set the supplier lead time on the item so future shortages show a sensible expected date instead of nothing. Make when the item has a recipe and you have capacity and materials for the sub-assembly.
Adjust only when you have evidence the physical count differs, for example after counting the bin. Adjusting stock to make a warning disappear hides the real process gap and will return as a negative or missing-cost problem later.
Preventing repeat shortages
Set reorder points and minimums for the parts that stop production most often, use the shortage views regularly rather than only when an order is stuck, and keep supplier lead times honest. Receive purchase orders the day goods arrive, in the correct location, so availability reflects reality.
For make-to-order businesses, confirm sales orders only after checking the promised date against component availability, not just finished goods. The shortage view on a sales order exists for exactly this decision.
Common pitfalls
- !Looking at total stock instead of stock at the manufacturing order's location.
- !Ignoring stock committed to other orders and then wondering why free stock is lower than on hand.
- !Adjusting stock to clear a warning instead of fixing the missing receipt.
- !Leaving purchase orders without expected dates, so the order shows no coverage at all.
- !Using a recipe unit that differs from the stock unit of measure.
- !Not creating a manufacturing order for sub-assemblies, so the parent order can never become available.
How an ERP-grounded AI assistant handles this
An ERPray-style assistant on a small ERP can answer which manufacturing orders are blocked, which ingredient is short, where stock for it actually sits, and which open purchase orders cover it, in one question, and it shows the query it ran. It reads by default and any purchase order or adjustment it suggests stays pending human approval. For a handful of orders, Katana's own shortage views are usually enough.
Frequently asked questions
What is the difference between expected and not available in Katana?
Expected means there is no free stock now, but an incoming purchase order or manufacturing order is scheduled to cover the need. Not available means neither free stock nor scheduled supply covers it, so you need to buy, make or correct stock.
Why does an ingredient show short when I can see it on the shelf?
Usually the receipt was not recorded, the stock sits in a different location than the order's production location, or it is committed to another order. Check stock by location and the committed quantity before adjusting anything.
Can I start a Katana manufacturing order with a shortage?
Katana lets you plan around shortages, but you cannot consume material that does not exist in stock without creating a negative or an adjustment. Resolve the shortage first so costs and stock stay accurate.
Does the order of manufacturing orders change what is available?
Yes. Availability is allocated against demand by priority and date, so a new urgent order can take stock from an older one. Review shortages after adding or rescheduling orders rather than assuming earlier status still holds.
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