Abstract:
A computerized system and method for managing parts shortages is disclosed. The computerized system and method analyzes inventory and production demand data over a period of time to whether the parts in inventory are sufficient to meet production demand. The projections allow a logistics provider to determine when parts shortages are likely to occur and the nature of the potential shortages. Information about the type and time of potential parts shortages allow the logistics provider to take action to prevent shortages entirely or minimize their impact on production. Some shortages may be covered by requesting delivery of parts from various locations within the site inventory or by locating parts within the site inventory. Other shortages may be covered by ordering more parts from suppliers. The ability to detect various types of shortages and take mitigating actions allow a logistics provider to maintain a flow of parts to production.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 12/240,852, filed Sep. 29, 2008, and titled SYNCHRONOUS AND OPTIMUM LINE DELIVERY UTILIZING TACT INFORMATION, which is incorporated herein by reference. This application claims priority to U.S. Provisional Patent Application No. 61/101,102, filed Sep. 29, 2008, and titled LOGISTICS PROVIDER PARTS DELIVERY AND MANAGEMENT SYSTEM, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to parts delivery management for assembly plants. More particularly, a computerized system and method is disclosed for identifying and managing parts shortages that may occur for different reasons. 
     BACKGROUND OF THE INVENTION 
     To keep production lines moving, manufacturers require delivery of the right part to the right place at the right time and in the right quantity. In conventional production lines such as automotive assembly lines, parts are added or assembled to a partially assembled product as it passes by assembly stations or areas on the production line. Associates working on the production line install parts and complete assembly processes as may be required to build a product meeting a particular set of specifications. A production schedule usually determines which manufacturer products will be built on a particular day or other production period and therefore, dictates which parts or components are needed on the production line so associates can complete the installation and assembly tasks at the assembly stations or areas. If an associate at an assembly station does not have the right parts at the right time, accommodations to the production process must be made. The product may be held or diverted to another location while attempts are made to locate the appropriate parts. Production slows or worse, may be halted entirely, as time is spent locating the appropriate part or parts to complete the necessary installation and assembly tasks. 
     To facilitate delivery of parts to the production line, some manufacturers work with a logistics provider that manages inventories of parts at the manufacturing facility and uses a variety of delivery techniques get parts from various inventory locations to production line locations when a need for replenishment is determined. For example, when the line side supply of a particular part at a particular location drops below a threshold, a replenishment method may be used in which an associate drives a vehicle loaded with the low inventory part to the particular production line location. Other manufacturers respond to replenishment requests using automated guided vehicles that deliver parts to assembly line locations based on directional information programmed into the vehicles. 
     Various right part, right place, right time (RPT) production methods have been developed to reduce costs attributable to maintaining replenishment inventories. RPT techniques involve coordinating the delivery of parts to the manufacturer&#39;s assembly plant as well as to “line side” locations in an effort to reduce inventory levels and, consequently, costs. Some manufacturers have incorporated parts consolidation centers into their RPT practices. Consolidation centers are facilities where parts are received from suppliers, staged for use in one or more assembly plants (i.e., organized according to the order in which they will be consumed), and then transported from the consolidation center to an assembly plant production line where they are consumed. 
     Although the logistics provider is responsible for delivery of parts from their arrival at the consolidation center to production line locations, the manufacturer typically orders the parts and supplies that are delivered to the consolidation center. The manufacturer orders parts and schedules delivery of the parts from suppliers as needed to maintain a flow of parts from the consolidation center to the production line. Although parts are ordered and scheduled for delivery according to the manufacturer&#39;s needs, what is delivered to the consolidation center and when it is delivered may be different than what was ordered for a variety of reasons. In some instances, parts deliveries to the consolidation center may be delayed due to weather, traffic, or even a wrong turn while en route to the consolidation center. In other instances, the supplier may not have provided all of the parts that were ordered. The parts may not have been loaded on the truck or they may not have been manufactured at all. Once at the consolidation center, parts may be misplaced during unloading or transportation to various points within the facility. 
     Part shortages attributable to delivery delays, quantity variances, misplacement, etc. may occur for various reasons. Although a logistics provider may undertake efforts to prevent or mitigate the impact of a parts shortage on production, the options available to the logistics provider depend upon a variety of factors. Some parts shortages may be corrected easily by locating the parts in overstock inventory or other inventory locations at the consolidation center. If the parts are not available in inventory, parts shipment data allows the logistics provider to determine whether an incoming shipment may be used to address the parts shortage. If no incoming shipments will arrive in time to address the parts shortage, the logistics provider may use an alternate source for the part. For example, the manufacturer may issue a new purchase order for the parts and expedite shipment of the parts. Once the parts arrive at the consolidation center, the logistics provider needs to arrange to have the parts delivered to the appropriate production line location so that production can continue uninterrupted. Therefore, it is important for the logistics provider to have detailed information about the parts shortage as well as for options to assist in recovering from the shortage. 
     Although the logistics provider may rely on one or more computer systems to manage many aspects of its parts delivery operations, the computer systems do not provide the features and functionality and detailed information needed to manage parts shortages. In particular, they do not provide features and functionality that allow a logistics provider to project when a parts shortage may occur or the nature of the shortage. There is a need for a computerized system and method provides a logistics provider with detailed information about parts shortages and when they may occur. There is a need for a computerized system and method that allows a logistics provider to receive information about parts shortages so that their impact on production can be analyzed. There is a need for a computerized system and method for determining whether a parts shortage is a critical parts shortage that could have an immediate impact production. There is a need for a computerized system and method that allows a logistics provider to manage parts shortage according to type so that arrangements can be made to avert critical parts shortages. 
     SUMMARY OF THE INVENTION 
     A computerized system and method for managing parts shortages furthers a logistics provider&#39;s goal of delivering the right part to the right production line location at the right time. In an example embodiment, a consolidation center for receiving parts from suppliers is co-located with an assembly plant. Data for parts received at the consolidation center are stored in an inventory database. Parts are received in trailers that are parked in a yard at the consolidation center. Parts are unloaded from the trailers and stored in various locations at the consolidation center until they are “picked” for delivery to production line locations. The inventory database tracks information about the location of the parts in the consolidation center as well as on the trailers in the yard. 
     Other databases that are used in the computerized system and method store have part demand data identifying the parts that are needed for production and when they are needed. The computerized system and method analyzes the inventory and production demand data over a period of time to whether the parts in inventory are sufficient to meet production demand. The projections allow the logistics provider to determine when parts shortages are likely to occur. The projections also allow the logistics provider to determine the nature of the potential shortages. Information about the type of parts shortages that may occur as well as information about when they may occur allows the logistics provider to take action to prevent shortages entirely or minimize their impact on production. Some shortages may be covered by requesting delivery of parts from various locations within the site inventory or by locating parts within the site inventory. Other shortages may be covered by ordering more parts from suppliers. The ability to detect various types of shortages and to take corrective or mitigating actions allow a logistics provider to maintain a flow of parts to production. As a result, the logistics provider increases the likelihood that a continuous supply of parts is made available to the associates that facilitate delivery of parts from the consolidation center to the production line. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a block diagram of a consolidation center inventory and delivery process for an example embodiment; 
         FIG. 2  is a schematic diagram for a short parts management operation for an example embodiment; 
         FIG. 3  is a potential short parts sheet for an example embodiment; 
         FIGS. 4A and 4B  are critical parts data sheets for an example embodiment; and 
         FIG. 5  is a block diagram illustrating a process for delivering parts located as a result of an identified parts shortage for an example embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , a block diagram of a consolidation center inventory and delivery process for an example embodiment is shown. One or more computer systems  100  may support the inventory and delivery process. A warehouse management system  102  tracks data related to movement of parts throughout the consolidation center as follows: 
     
       
         
               
             
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Warehouse Management System Data 
               
             
          
           
               
                 Process 
                 Description 
               
               
                   
               
               
                 Inbound 
                 Parts arrive (in containers) on inbound trailers. WMS  
               
               
                   
                 102 has data for each inbound trailer and the parts loaded  
               
               
                   
                 in the trailer. 
               
               
                 ADC 
                 Trailers are processed through an arrival and departure  
               
               
                   
                 center. 
               
               
                 Yard 
                 Trailers with parts are temporarily stored in the yard. Each  
               
               
                   
                 trailer is assigned a location in the yard and each trailer&#39;s  
               
               
                   
                 location in the yard is recorded in WMS 102. 
               
               
                 QC, Small Lot, 
                 Special handling for parts. Certain parts may be inspected  
               
               
                 Demand Re- 
                 or re-packed. 
               
               
                 pack, and Re- 
                   
               
               
                 pack 
                   
               
               
                 Putaway 
                 Containers of parts are stored in delivery inventory areas  
               
               
                   
                 at the consolidation center to facilitate a pick/pack  
               
               
                   
                 operation. Each container&#39;s location in the consolidation  
               
               
                   
                 center is recorded in WMS 102. The containers are in an  
               
               
                   
                 area available to associates completing the pick/pack  
               
               
                   
                 operations. 
               
               
                 Pick/Pack 
                 Containers are selected or “picked” from delivery  
               
               
                   
                 inventory or putaway locations for delivery to the  
               
               
                   
                 production line. Associates use a computer generated  
               
               
                   
                 “pick/pack” check sheets that identifies the part containers  
               
               
                   
                 to load on a cart by or at a specified time. Containers may  
               
               
                   
                 be loaded on multi-shelf carts that are connected to form a  
               
               
                   
                 train pulled by a tugger to the production line. 
               
               
                 AF-On 
                 Parts are delivered line side and then used in assembly  
               
               
                   
                 operations during the production period. 
               
               
                   
               
             
          
         
       
     
     A delivery management system  104  tracks data related to the transportation of parts from the consolidation center to the production line as follows: 
     
       
         
               
             
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                 Delivery Management System 
               
             
          
           
               
                 Process 
                 Description 
               
               
                   
               
               
                 Train Building 
                 Trains comprising a plurality of cart types are assembled  
               
               
                   
                 throughout the production period and loaded with parts  
               
               
                   
                 containers that are delivered line side. Trains are  
               
               
                   
                 reconfigured throughout the production period and parts  
               
               
                   
                 are delivered when needed to the appropriate production  
               
               
                   
                 line locations. The delivery management system 104  
               
               
                   
                 receives manufacturer production schedule data as well as  
               
               
                   
                 part and container data to determine which parts are  
               
               
                   
                 needed and when they are needed. Lead times for  
               
               
                   
                 delivering parts to different line side locations are  
               
               
                   
                 determined and used in configuring carts for each train  
               
               
                   
                 that transports the parts. 
               
               
                 Pick/Pack 
                 Containers are selected or “picked” for delivery to the  
               
               
                   
                 production line. Associates use a “pick/pack” check sheets  
               
               
                   
                 that identifies the part containers to load on a cart by or at  
               
               
                   
                 a specified time. Containers may be loaded on multi-shelf  
               
               
                   
                 carts that are connected to form a train that is pulled by a  
               
               
                   
                 tugger to the production line. 
               
               
                 Staging 
                 Organize carts and trains for delivery of parts to  
               
               
                   
                 production line side locations. 
               
               
                 Deliver 
                 Tuggers pull multi-cart trains to specified production line  
               
               
                   
                 locations identified on the parts containers. 
               
               
                 ADN 
                 Parts are delivered line side throughout the production  
               
               
                   
                 period. 
               
               
                   
               
             
          
         
       
     
     Data from several sources is used to project parts shortages and to identify actions to prevent or mitigate the impact of shortages. An inventory database  108  comprises location and quantity data  112  for the parts  110  used in production. In the example shown, 120 units of part 12345-SH3-A000: NH167L each are in trailers 101 and 321 in the yard and 90 units of part 12345-SH3-A000: NH167L are in delivery inventory in putaway location A101 for a total of 330 units in consolidation center inventory. An order generation database  114  comprises pick/pack time and demand data  116  for the parts used in production. The pick/pack time and demand data  116  identifies when the specified quantity of parts should be selected from the delivery inventory in putaway locations for delivery to the production line. In the example shown, 30 units of the part are selected for delivery every half hour from 9:00 to 10:30. Finally, an advanced shipping notice (ASN) database  118  comprises information about shipments of parts and their estimated delivery dates and times. The ASN database  118  has identifying information for trailers, estimated times of arrival, part number, and units  120 . 
     The data in the inventory database  108  and order generation database  114  may be used to project when the delivery inventory putaway locations for a part will be depleted and therefore, when parts are needed for the delivery inventory putaway location to maintain the flow of parts to production. For example, if the parts in putaway location A101 (90 units) are applied to the production demand data for the part (30 units at 9:00, 30 units at 9:30, and 30 units at 10:00, 30 units at 10:30), the delivery inventory in putaway location A101 will be depleted at 10:00. Therefore, additional inventory must be provided to delivery inventory before 10:00 for the pick operation to continue after 10:00. The projection information may be used to determine when potential parts shortages will occur and therefore, what actions are needed to ensure that parts continue to be available in the consolidation center delivery inventory to support the pick operation and the flow of parts to production. 
     Referring to  FIG. 2 , a schematic diagram for a short parts management operation for an example embodiment is shown. Data from an order generation and inventory computer system  130  is compared against production demand data  132  to determine when delivery inventory for each part may be depleted. Staging clock and lead time comparison data  138  is used to analyze the potential parts shortages that may occur. The results of the comparisons are used to determine a type of parts shortage  136  which is recorded in the computer system  134 . Parts may be identified as “short” within the consolidation center  148  or in the assembly plant  150 . A “short identified time line”  148 ,  150  indicates how short types may be determined and assigned. The time line data provides an indication of the amount of time available to the logistics provider to avert the shortage entirely or minimize the impact of the shortage. 
     
       
         
               
             
               
               
               
               
             
           
               
                 TABLE 3 
               
             
             
               
                   
               
               
                 Short Types 
               
             
          
           
               
                   
                   
                 Consolidation 
                 Assembly  
               
               
                   
                   
                 Center Time  
                 Plant Time  
               
               
                 Short Type 
                 Description 
                 Line 
                 Line 
               
               
                   
               
               
                 True Short 
                 No inventory for part at  
                 &gt;4 hours 
                 &gt;2 hours 
               
               
                   
                 consolidation center (in putaway  
                   
                   
               
               
                   
                 locations, in-house (overstock),  
                   
                   
               
               
                   
                 or in yard) 
                   
                   
               
               
                 Potential  
                 No delivery inventory in putaway  
                 2-4 hours 
                   
               
               
                 Short 
                 locations but inventory available  
                   
                   
               
               
                   
                 in-house or in yard. Use demand  
                   
                   
               
               
                   
                 pegging operation to request  
                   
                   
               
               
                   
                 delivery of part from storage  
                   
                   
               
               
                   
                 inventory (overstock or yard) so  
                   
                   
               
               
                   
                 part is available in delivery  
                   
                   
               
               
                   
                 inventory. 
                   
                   
               
               
                 Critical Part 
                 Pick/Pack Time Short-part  
                 1-2 hours 
                 &lt;1 hour 
               
               
                 Short 
                 missed at point of picking from  
                   
                   
               
               
                   
                 delivery inventory in putaway  
                   
                   
               
               
                   
                 location. Part is available from  
                   
                   
               
               
                   
                 storage inventory (overstock or  
                   
                   
               
               
                   
                 yard) but must be located. 
               
               
                   
               
             
          
         
       
     
     Once the short type is determined, an inventory control system modification application  142  generates a “short summary” document to assist the logistics provider in determining a possible resolution. For “true short” types, arrangements may be made to order the needed part or parts from a supplier or an alternate source for the part. The logistics provider may arrange to expedite shipment of the part to the consolidation center so that it may be transported directly to delivery inventory in putaway location or to the production line. For “potential short” types, a potential short sheet  144  identifying the needed parts is generated. The potential short sheet is used to monitor a process that is behind schedule in which the parts are requested from storage inventory (e.g., overstock or the trailer yard) to prevent a “critical part short.” Process times for transporting parts from the storage inventory (e.g., overstock or the trailer yard) to the delivery inventory in putaway locations are used to determine when the parts from the storage inventory locations should be requested so they are available for picking at the indicated pick/pack time. The request may be added to a task sheet to notify an associate of the need. The associate then arranges to complete the task by the noted time. Finally, for a “critical part short” type, a short sheet and cycle count sheet  146  are generated to facilitate locating the parts in inventory. Once the parts are located, they may be picked for line side delivery. 
     A user of the inventory control system modification application may review several screens that assist the user in monitoring and viewing information about true, potential, and critical short parts. A receiving schedule identifies the status of trailers that are moved from a yard to receiving docks and unloaded to replenish inventory at the consolidation center. The trailers may be moved from the yard to receiving docks as a result of a demand pegging operation in which parts that are identified as needed in production are selected, transported from the yard to a dock, and unloaded to replenish parts that are needed according to production demand data. The receiving schedule allows a user to monitor the status of the trucks that have been pegged to ensure they are unloaded according to the schedule determined from the demand pegging operation. 
     
       
         
               
             
               
               
             
               
             
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 4 
               
             
             
               
                   
               
               
                 Receiving Schedule 
               
             
          
           
               
                 RECEIVING SCHEDULE 
                 Jun. 25, 2009 7:39 
               
             
          
           
               
                 Wh / CO / DV: XXX XXX XXXXXXXX 
               
               
                 Press 1 and Enter to view details 
               
             
          
           
               
                 Opt 
                 Trailer 
                 Devan Date/Time 
                 SCAC 
                 Trailer 
                 Dock 
                 Door 
                 UserID 
               
               
                   
               
             
          
           
               
                 — 
                 Inb - Door 
                 06/23/09  
                 7:16 
                 ABC 
                 KKX123 
                 C1 
                 001 
                 UID1 
               
               
                 — 
                 Inb - Door 
                 06/23/09  
                 9:35 
                 DEF 
                 COS988 
                 C1 
                 002 
                 UID2 
               
               
                 — 
                 Inb - Door 
                 06/23/09  
                 9:38 
                 GHI 
                 CC101 
                 C1 
                 003 
                 UID3 
               
               
                 — 
                 Inb - Door 
                 06/23/09  
                 9:21 
                 ABC 
                 KKX125 
                 C1 
                 004 
                   
               
               
                 — 
                 Inb - Door 
                 06/23/09  
                 9:38 
                 ABC 
                 KKX127 
                 C1 
                 005 
                   
               
               
                 — 
                 Inb - OnYar 
                 06/23/09  
                 9:48 
                 JKL 
                 PMN233 
                   
                   
                   
               
               
                 — 
                 Inb - Door 
                 06/23/09  
                 9:49 
                 DEF 
                 COS978 
                 C1 
                 006 
                   
               
               
                 — 
                 Inb - Door 
                 06/23/09  
                 9:56 
                 ABC 
                 KKX129 
                 C1 
                 007 
                   
               
               
                 — 
                 Inb - Door 
                 06/23/09  
                 10:00 
                 GHI 
                 UOP009 
                 C1 
                 008 
                 UID4 
               
               
                 — 
                 Inb - Door 
                 06/23/09  
                 11:14 
                 DEF 
                 COS968 
                 C1 
                 009 
                   
               
               
                 — 
                 Inb - OnYar 
                 06/23/09  
                 11:15 
                 ABC 
                 KKX140 
                   
                   
                   
               
               
                 — 
                 Inb - OnYar 
                 06/23/09  
                 12:05 
                 DEF 
                 COS998 
                   
                   
                   
               
               
                 — 
                 Inb - OnYar 
                 06/23/09  
                 12:06 
                 GHI 
                 XRT404 
                   
                   
                   
               
               
                 — 
                 Out - Door 
                 0/00/00  
                 00:00 
                 STR 
                 DXO887 
                 C1 
                 061 
                   
               
               
                   
               
             
          
         
       
     
     A user may view details for a shipment by selecting it from the list of shipments in the receiving schedule. The shipment details identify the shipment and its status as well as details regarding the receipt of the shipment (when it was expected and when it arrived) and the number of cases (actually shipped and received). 
     
       
         
               
             
               
               
             
               
             
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 5 
               
             
             
               
                   
               
               
                 Shipment Details 
               
             
          
           
               
                 SHIPMENT DETAILS  
                 Jun. 25, 2009 7:45 
               
             
          
           
               
                 Wh / CO / DV: XXX XXX XXXXXXXX 
               
               
                 Press 1 and Enter to view details 
               
             
          
           
               
                   
                   
                   
                   
                   
                   
                 Cases 
                 Cases 
               
               
                 Opt 
                 Shipment 
                 Status 
                 First Rcpt 
                 Expected Rcpt 
                 Vendor 
                 Shipped 
                 Received 
               
               
                   
               
             
          
           
               
                 — 
                 1366 
                 40 In Recv 
                 06/23 
                 06/22 
                 0334 
                 70 
                 65 
               
               
                 — 
                 5257 
                 20 Appt Sche 
                 00/00 
                 06/22 
                 0709 
                 2 
                 0 
               
               
                 — 
                 2252 
                 20 Appt Sche 
                 00/00 
                 06/22 
                 0506 
                 44 
                 0 
               
               
                 — 
                 0985 
                 40 In Recv 
                 06/23 
                 06/22 
                 0928 
                 32 
                 32 
               
               
                 — 
                 3847 
                 20 Appt Sche 
                 00/00 
                 06/22 
                 5678 
                 29 
                 0 
               
               
                   
               
             
          
         
       
     
     A “short parts summary” screen allows a user to view information about short parts. Visual indicators such as bold text and italicized text may be used to quickly communicate information about short parts. Reverse highlighting may be used for individual entries as delivery or pick times approach. The shorts parts summary screen provides the information that allows an associate to prioritize the most critical activity. Information about potential and true shortages allows the associate to take actions to prevent them from becoming critical parts shortages. The screen display is updated as information related to the entries changes. 
     
       
         
               
             
               
               
             
               
             
               
               
             
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 6 
               
             
             
               
                   
               
               
                 
                   Sample 
                   Short 
                   Parts 
                   Summary 
                 
               
             
          
           
               
                 
                   SHORT 
                   PARTS 
                   SUMMARY 
                 
                 
                   JUN 
                   25, 
                   2009 
                   9:39 
                 
               
             
          
           
               
                 Wh / CO / DV: XXX XXX XXXXXXXX 
               
             
          
           
               
                 Press 1 and Enter to view details 
                   Critical   Parts   (CPI),   Potential   Short,  True Short 
               
             
          
           
               
                 
                   Opt 
                 
                 
                   CTRL 
                   # 
                 
                 
                   Supplier 
                 
                 
                   Part 
                   # 
                 
                 
                   Color 
                 
                 
                   Qty 
                 
                 
                   Lot 
                 
                 
                   Pick/Train 
                 
                 
                   CST 
                 
               
               
                   
               
             
          
           
               
                 — 
                 
                   C99991 
                 
                 
                   99999991 
                 
                 
                   AOXX1 
                 
                 
                   CC100 
                 
                 
                   30 
                 
                 
                   200901 
                 
                 
                   06/25 
                 
                 
                   10:00 
                 
               
             
          
           
               
                   
                 
                   ABC 
                   Supply 
                 
                 
                   Wheel 
                   Assembly 
                 
                 
                   St: 
                   XX 
                 
                 
                   Cd:X 
                 
               
             
          
           
               
                 — 
                 
                   C99992 
                 
                 
                   99999992 
                 
                 
                   BOXX2 
                 
                 
                   CC101 
                 
                 
                   30 
                 
                 
                   200901 
                 
                 
                   06/25 
                 
                 
                   11:28 
                 
               
             
          
           
               
                   
                 
                   DEF 
                   Supply 
                 
                 
                   Trunk 
                   Assembly 
                 
                   St: ____________ 
                 
                   Cd:X 
                 
               
             
          
           
               
                 — 
                 
                   C99993 
                 
                 
                   99999993 
                 
                 
                   COXX3 
                 
                 
                   CC101 
                 
                 
                   30 
                 
                 
                   200901 
                 
                 
                   06/25 
                 
                 
                   12:07 
                 
               
             
          
           
               
                   
                 
                   GHI 
                   Supply 
                 
                 
                   Visor 
                 
                   St: ____________ 
                 
                   Cd:X 
                 
               
             
          
           
               
                 — 
                 P99991 
                 99999994 
                 DOXX4 
                 CC102 
                 30 
                 200901 
                 06/25 
                 12:12 
               
             
          
           
               
                   
                 JKL Supply 
                 Door Handle 
                 St:____________ 
                 Cd:X 
               
             
          
           
               
                 — 
                 T99992 
                 99999995 
                 EOXX5 
                 CC103 
                 30 
                 200901 
                 06/25 
                 12:16 
               
             
          
           
               
                   
                 MNO Supply 
                 Cover 
                 St: XX 
                 Cd:X 
               
             
          
           
               
                 — 
                 T99993 
                 99999996 
                 FOXX6 
                 CC104 
                 30 
                 XXXXX 
                 XX/XX 
                 13:43 
               
             
          
           
               
                   
                 PQR Supply 
                 Wheel Cover 
                 St:____________ 
                 Cd:X 
               
               
                   
               
             
          
         
       
     
     A user may select a details option to get further details about a specific part. 
     
       
         
               
             
               
               
               
             
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE 7 
               
             
             
               
                   
               
               
                 Short Part Detail 
               
             
          
           
               
                   
                 Short Type: 
                 Critical Part 
               
               
                   
                 Train: 
                 TB002205 
               
               
                   
                 Part #: 
                 AOXX1 
               
               
                   
                 Description: 
                 Wheel Assembly 
               
             
          
           
               
                 CML 
                 MCID 
                 Quantity 
                 Pick Date 
                 Pick Time 
                 Train Date 
                 Train CST 
               
               
                   
               
             
          
           
               
                 TMB00220022 
                   
                 30 
                 06/23 
                 08:54 
                 06/23 
                 10:00 
               
               
                   
               
             
          
         
       
     
     Referring to  FIG. 3 , a potential short parts sheet for an example embodiment is shown. A potential short sheet is generated when the computerized system and method determines that on-site inventory for a particular part is sufficient to meet production demand but is not in delivery inventory in a putaway location and ready to be picked. The potential short parts sheet identifies the potential part shortage by control number  160  and provides information about the part  162 . It further provides information about the quantity needed and the production lot for which the part is needed  164 . Finally, the potential short sheet provides information about locations in the consolidation center inventory where the part may be located  166 . Using the part and location information, an associate can issue a request to obtain the parts from one of the identified locations. The request may result in a task assigned to another associate that is responsible for managing the inventory location. The assigned task may indicate when the identified parts are needed in a delivery inventory putaway location so they are available to be picked at the indicated “critical pick time.” An associate may arrange to have the parts transported from the identified location to a delivery inventory putaway location in time to be picked for production. The part identification, pick time, and location data allows the logistics provider to make arrangements to have the parts available when needed. Finally, the potential short parts sheet provides a summary of the total inventory of the part available at the consolidation center  168 . In-house nettable parts are parts that meet the manufacturer&#39;s quality standards while in-house non-nettable parts may not meet the manufacturer&#39;s quality standards or are otherwise suspect. 
     Referring to  FIGS. 4A and 4B , critical parts data sheets for an example embodiment are shown. A critical part shortage occurs when the part should be picked but is not available in the delivery inventory putaway location. The critical parts data sheets assist the logistics provider with fulfilling the need for the part identified on the sheet. Referring to  FIG. 4A , a critical parts information short sheet for an example embodiment is shown. The sheet identifies the part  170  and delivery data for the part including the quantity needed, the associated lot number, train identifying and cart identifying (cart master label) data for transporting the part, and a production line side delivery location for the part  172 . The sheet further identifies on site locations of the part  174  and provides a summary of the total inventory of the part available at the consolidation center  176 . The sheet also has a list of specific inventory locations where the part may be located. An associate may check these areas to determine whether the part is available in any of the areas. Finally, the sheet provides administrative details such as an issuer, identifying information for short parts associate that investigates the shortage, and status information  180 . 
     Referring to  FIG. 4B , a critical parts information cycle count sheet for an example embodiment is shown. The sheet identifies an inventory area where the part is identified as present  190  and provides detailed part data including a bar code  192 . The sheet further specifies inventory areas where the part is identified as missing  194 . Finally, the sheet provides a series of tasks  196  that an associate can complete to determine whether there is an inventory discrepancy or the parts were lost during transit. 
     Referring to  FIG. 5 , a block diagram illustrating a process for delivering parts located as a result of an identified parts shortage for an example embodiment is shown. The inventory control system modification application executing at a WMS computer  206  provides directions to an associate for managing the parts shortages. A potential part shortage is resolved when the identified part is located in on-site inventory (e.g., overstock or yard) and transported to delivery inventory in a putaway location in advance of the part pick time. The application then directs the associate to close the potential part shortage record. 
     When the consolidation center receives the parts associated with a true short, they are transported to a designated short parts area  208  for special handling. For critical part shortages, when the parts are located within the consolidation center inventory, they are also transported the designated short parts area  208  for special handling. The application indicates to an associate where parts will be directed for special handling. 
     Information regarding the parts shortage is coordinated with information in other computer systems  210  to facilitate the delivery of the parts according to a special handling procedure. The critical short sheet identifies the train number, cart, and line side location for the short part delivery. A train dispatching application displays schedule information for the short parts train that will be dispatched to deliver the parts line side. Different delivery vehicles may be used depending on the size of the parts to be delivered line side. Small parts may be loaded on a shelf of a particular cart attached to a train  212  while large parts may be placed on a cart that is then attached to a train  214 . 
     In the train staging phase  216  of short parts handling for small parts, the parts container is scanned to the cart master label of a cart  218 , the part container is loaded on the assigned cart, and the WMS computer is updated to reflect the loading of the parts container on the cart. For large parts, the train and cart are scanned to the cart master label, the cart is attached to the train, and the WMS computer is updated to reflect the attachment of the cart to the train  220 . 
     In the assembly line side delivery phase of short parts handling, if the cart is available in the short parts area  222 , the parts container is scanned to a cart master label. The cart is delivered and scanned to the line side delivery location. Once scanning is completed an advanced delivery notice is sent to the WMS computer to reflect the delivery of the parts  224 . If the cart is not available, the “critical short parts” control number is scanned to confirm the correct part and quantity for delivery. The parts container is delivered to the line side delivery location and is scanned to a cart master label and then to the delivery line location. Once scanning is completed an advanced delivery notice is sent to the WMS computer to reflect the delivery of the parts  226 . 
     An exemplary embodiment of a computerized system and method for managing parts shortages has been shown and described above. It should be realized by one skilled in the art that various modifications may be made to the computerized system and method described above as well as data items and databases used in the analysis. Changes to the method for determining parts shortages as well as classifying shortages may be made and fall within the scope of the claimed invention. In addition, documents that are generated in relation to identified parts shortages may be modified in various ways and fall within the scope of the claimed invention. Special handling procedures may be modified as well. Therefore, while certain embodiments of the present invention are described in detail above, the scope of the invention is not to be considered limited by such disclosure, and modifications are possible without departing from the spirit of the invention as evidenced by the following claims: