Stock levels are a solved problem — your ERP does that well. What it cannot tell you is why consumption of a material moved: which machine drew it, against which job, and whether the quantity that left the store ever matched the quantity the floor actually used.
Your ERP shows the spare left the store, booked to a cost centre.
It won't tell you which machine ate it, or why that machine started eating them twice as fast.
Why the gap existsThe three numbers
These are three separately captured numbers, not one number viewed three ways. Munshi puts them side by side per material so the divergence is visible instead of averaged away.
What came in against a purchase, recorded at the store as inbound stock movement.
What the store handed out to production. Recorded when it leaves, against the material note that authorised it.
What the floor reported using, on approved production reports — tied to the machine and the catalogued item, not to a free-text note.
Issued and consumed are captured independently and by different people, so they are not expected to agree exactly. That is the point: Munshi shows the variance per material rather than forcing the two to balance, because a number that has been forced to balance has stopped telling you anything. A material whose issued figure keeps running ahead of consumed is worth a walk to the store.
What Munshi surfaces
Teal is normal, maroon is flagged. Illustrative data.
The variance column is the one to read. Two materials here are drifting apart.
Normalised against what the machine actually produced, so a busy month doesn’t read as a problem.
Production consumption, split by the machine that consumed it.
How it is captured
Store, zone, aisle, rack, shelf and bin. Use as much of that depth as your store actually has — a single store with no bins is a legitimate setup, not a half-finished one.
A material request carries its own status and its own approval state, so “approved” and “closed” are different questions. An approved request can become a purchase requisition without being re-keyed.
A consumption line points at an item in your catalogue, and the choices can be constrained per machine — so the same spare is the same spare across every report, and the wrong one isn’t offered.
Because a production consumption line is tied to the report it came from, and the report is tied to an asset, consumption rolls up per machine without anyone tagging it — which is what makes “this machine’s consumption changed” a question you can answer at all.
Get started
Find the material that doesn’t add up.
Pick one you already suspect. Issued against consumed, per machine, is usually where it shows.