When one component is late, the whole line waits.
Discrete manufacturers run on bills of materials. One missing component, one overloaded work center, one supplier drift, and the schedule unravels. WERISCO watches the chain from component to customer order.
Inventory · Production · Supplier lead time · Materials · Capacity
How the chain actually behaves
A mid-market manufacturer typically runs an ERP for orders and finance, MRP logic for requirements, and a layer of spreadsheets where planners actually decide. The gap between them is where shortages hide: the MRP says the part is ordered, the spreadsheet says the line starts Monday, and nobody has compared the supplier's real delivery history with either.
- 01
Component shortages at release
Orders released to the floor without every component on hand stall mid-build and tie up WIP.
- 02
MTS / MTO conflicts
Stock replenishment competes with customer orders for the same capacity and the same components.
- 03
Bottleneck blindness
The constraining work center is known to the shift lead, not to the plan.
- 04
Stale lead times
ERP lead times set at supplier onboarding, years ago.
From a late supplier order to a chase list
- Step 01
Supplier confirms the PO for component C-220 five days late
- Step 02
WERISCO compares the new date with stock on hand: 3 days of cover
- Step 03
Ranks the PO first, with stock, usage, cover and dates as evidence
- Step 04
Recommends chasing the supplier and checking alternative stock
- Step 05
Planner approves; the team decides what to change in the schedule
industrial pumps manufacturer
$80M revenue, 2 plants, 4,200 active SKUs, 310 suppliers.
- 01Casting supplier slips 9 days
- 023 pump assemblies lack housings
- 03Line 3 idles 2 shifts
- 042 key-account orders miss date
Swap orders 7731/7736, expedite 40% of castings, notify 2 accounts.
- Schedule adherence
- Shows whether the plan survives contact with reality.
- Material availability at release
- The leading indicator of stalled orders.
- OTIF to customer
- What your customers actually measure you on.
- WIP value
- Cash stuck between raw material and finished goods.
- Single-sourced electronic or cast components
- Lead-time drift at tier-1 suppliers
- Capacity overload at the constraint
- Engineering changes invalidating stock
Signals · BOM explosion vs on-hand · Work-center load · Supplier confirmation gaps · WIP aging
Supply chain audit
See where your supply chain is exposed.
A 20-minute call and two file exports: stock by item and open orders. You see the inventory and order value exposed. No integration, no savings estimate, and an NDA if you need one.