Stock and Material

A Part is any item or component tracked in Pelico. Almost everything else in the platform is attached to a Part : an order that produces it, an order that consumes it, its stock, its coverage, its projection.

Pelico classifies parts by where they sit in your production, not by what they are.

💡The same physical item can be a component in one plant and an equipment in another. The type describes its position in a Bill of Materials, not the item itself.

The Bill of Materials, or BoM, is the list of components and quantities needed to produce one unit of a part.

If producing one MODEL1 requires four Component_1 and two Component_2, then a Work Order for five MODEL1 needs twenty Component_1 and ten Component_2. Pelico derives these quantities from the BoM rather than from the order itself.

The BoM is also what makes a small shortage a big problem. A missing component blocks the sub-assembly that needs it, which blocks the equipment above, which puts the customer order at risk. This is how one part deep in your BoM reaches a customer commitment.

Pelico receives your current stock from your source system. That figure is the starting point for everything Pelico calculates about that part.

Starting point is the important phrase. Pelico does not stop at your current stock, it replays every planned event on top of it. So the stock figure you see for a given date is a calculation, not a measurement.

⚠️ The figure shown for today can differ from what is physically on your shelves today. Pelico replays every event at its planned date, including orders that were planned in the past and never rescheduled. Overdue orders that nobody moved are the usual explanation. See Stock Projection.

Stock accuracy in your source system flows straight into every Pelico calculation. If a stock count is wrong upstream, every coverage status built on it will be wrong too.

This is the section that answers the most common question about stock in Pelico : the part is on the shelf, so why is my order blocked ?

There are two different answers, and keeping them apart saves a lot of confusion.

Some stock of the part exists, but Pelico does not treat it as available supply. And some stock is not the part at all, but could replace it, in which case Pelico shows it to you as a suggestion instead of using it.

In some production modes, specific physical parts are reserved to build one specific equipment. This is called Make-to-Order, and the Serial Number is what links an equipment to the parts assembled into it.

Here, stock is no longer interchangeable. A hundred parts of the right reference are useless to a Work Order if none of them carry the right serial number. A Work Order is covered only when all the parts carrying the matching serial number are available.

💡If you work in a Make-to-Order environment, a blocked order next to plenty of visible stock is usually a serial number question, not a quantity question.

Some quantities become available only once they have passed quality inspection. Pelico treats that release as an event with its own date, which means the stock counts from the release date rather than from today.

A Quality Note can also flag quality information or a constraint affecting a part or an event.

Some storage locations are deliberately left out of Pelico's calculations. Exclusion is defined per plant and per storage location, so the same kind of location can be excluded at one plant and counted at another.

When a location is excluded, its stock still exists in your systems, but Pelico does not count it as available supply anywhere.

This is a configuration choice made for your organization. It is not something you can change from your own settings, and not every organization uses it.

A stock link key segments the stock of a part inside a plant, so that specific stock is set aside for specific needs. Every stock quantity and every supply or demand event can carry a key, and Pelico only matches a supply to a need when their keys are compatible. Stock with no key stays available to any need.

This means you can have stock of the right part, in the right plant, and still have a blocked order, because that stock is segmented for something else. You can see these keys on the Part 360 view and in the coverage view.

Pelico can also see stock that is not the part you need, but could stand in for it.

⚠️ Neither alternate part stock nor rotable stock is counted in coverage or in the stock projection. An order can therefore stay blocked while an alternate sits in stock. Pelico is telling you the option exists. Deciding to use it stays your call.

When several orders need the same part, Pelico allocates supply first in, first out by default : the earliest need is served first.

Your environment can add allocation constraints or priority rules on top of that default. This is why raising the priority of one order can move a scarce part away from another order, and why the same stock can serve a different order tomorrow.

See Pelico’s Algorithms for how these links are built and rebuilt.

A Stock Transfer Order moves stock between two of your own locations. It has a sending side and a receiving side, so it reduces stock at the origin and increases it at the destination.

A transfer moves through five steps.

The sending side and the receiving side are independent. The quantity stops counting at the origin when the goods ship. It starts counting at the destination when they arrive and are put away, which a processing delay can push slightly later.

⚠️ Between shipping and delivery, the quantity counts at neither end. It has left the origin and has not arrived yet. This is expected behaviour, not a data error, and it explains transfers that look like they made stock disappear.

Pelico can also point out when a part you are short of is available at another plant. That suggestion is a Stock Transfer Opportunity, described in Production Control Usage Scenarios.