Kitting Shortage List Template
Kits stall when one part is missing, and the shortage list is how planners, buyers and the floor agree what to chase. This template tracks each line's required and allocated quantity and calculates the shortage and its value.
| Kit or work order | Part number | Required (units) | Allocated or picked (units) | Short (units) | Fill rate | Unit cost | Value short | Promised receipt | Action | Owner | |
|---|---|---|---|---|---|---|---|---|---|---|---|
150 | 62.5% | $623 | |||||||||
0 | 100% | $0 | |||||||||
120 | 0% | $1,416 | |||||||||
30 | 75% | $1,155 | |||||||||
20 | 66.7% | $535 |
Review at the start of each shift. A kit is clear to build only when every line has fill rate 100 percent, or when production has agreed to a partial kit. Remove lines once the shortage is closed in the ERP so the list stays short.
Live shortage board from your ERP
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How to use the template
Add a row for every kit line that is short or at risk. Enter the required quantity from the work order or kit pick list, the allocated or picked quantity, and the unit cost. The sheet calculates the shortage, the fill rate and the value short. Add the promised receipt date from the supplier and an owner. Sort by promised date to see which kits can start and which cannot.
Why it works
A shortage list is a daily management tool, not a report. The key fields are the real quantity short, the date the part will really arrive, and one named owner. The value short column helps decide where to spend expediting money. The action column keeps decisions explicit: expedite, substitute, transfer, build partial or wait for inspection.
- Fill rate shows how close each line is to complete.
- Value short supports expedite decisions.
- Owner and date prevent lines from being forgotten.
Reading the example
In the sample, WO-77120 is short 150 bearings with a promised date of 28 October, so the kit cannot complete before then unless a partial build is agreed. WO-77133 has two problems: a cable not yet ordered, which is a planning failure, and a PCB sitting in inspection, which is a quality queue issue and may release sooner than the supplier date suggests.
Common mistakes
The usual failures are stale promise dates, shortages recorded only as a part number with no quantity, and different lists kept by planning and the floor. Another is treating on hand as available when it is reserved for another order. Allocate in the ERP first, then record the leftover shortage here.
Frequently Asked Questions
What is a kitting shortage list?
It is a list of kit components that cannot be picked in full for a work order, showing quantity short, expected arrival and who is resolving each line. It tells production which kits are clear to build.
What does clear to build mean?
A work order is clear to build when all required components are available, allocated and, where needed, inspected. Some plants allow a partial kit if the missing parts are not needed until later operations.
How often should the shortage list be updated?
At least once per shift for the next several days of production, and when receipts are posted. A list that is updated weekly is usually out of date by the time anyone acts on it.
Should shortages be tracked in Excel or the ERP?
The ERP is the source of truth for quantities, and most have a shortage report. Excel is useful for adding promise dates, owners and actions that the ERP does not hold. Use both without double entry of quantities.
Netray can generate a live shortage view from your ERP's work order and inventory data so the list updates itself instead of being maintained by hand.
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