Short Orders Avoidance using a Lean Manufacturing Approach

How to Prevent Short Orders


In this article, you will learn what is short order and how to avoid them using lean manufacturing techniques and six sigma tools.

Short Orders Definition

Short orders are defined as customer product orders confirmed between the manufacturer and the client, but which cannot be manufactured on time or as scheduled due to one or more components materials not available on hand.

A short order occurs when you receive a number of items below the number you ordered.

It results in delayed customer deliveries since you cannot complete the manufacturing process due to a lack of components or parts necessary.

A short order could result that not all customer orders could be fulfilled.

If you receive a short order, the number of items you receive is below the number you ordered.

It is considered a type of hold order and wastes undesired by every manufacturer.

6 Factors That Trigger Short Orders

In addition, the following 6 factors can trigger many short orders:

    1. Having standing inventory (wasting space and resources).
    2. Making unusable by-products.
    3. Spreading out your workstations too much, increasing the travel time between them.
    4. Production queues backing up due to bottlenecks.
    5. Too many workers being assigned to a limited task.
    6. Lacking process automation where it can be used.

10 Key Elements to Reduce and Avoid Short Orders.

Preventing short orders is not easy and requires the implementation of several lean manufacturing techniques, such as:

    1. Eliminate waste
    2. Kaizen (continuous improvement)
    3. Respect human elements
    4. Heijunka (level production)
    5. JIT (Just In Time) production
    6. One-piece flow
    7. Quality built-in
    8. Poka-Yoke (mistake proofing)
    9. Jidoka (detecting defects through automation)
    10. Improve the lean manufacturing cycles

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CIQA is a quality and regulatory consultant with 25 years of experience developing products and managing projects in the medical device supply chain, and pharmaceutical industries. Rest assured of the safety or being in the right hands.

Our Lean Manufacturing team could provide you a broad range of professional expertise implementing these techniques and tools.


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Quality procedures templates

Three (3) Options to Create Document Control Management DCM Procedures:

Bronze Option. You Can Create Your Own Quality Procedures, using a Template.

You can download samples of the Document Control Management DCM procedure templates in .pdf format. 

To see the complete list of the most popular quality procedures templates, click here.

In addition, you can request a quotation to buy online a full SOP template document in MS Word format that is completely editable, ready to fill, and adapt to your specific needs.

Silver Option. We Can Bring You Formal Training about short orders.

This option is recommended if you want to learn more about how to build robust quality system procedures. One of our expert(s) can provide online step-by-step training to your team (unlimited assistance) on how to build reliable SOPs using our template(s). Also, you can improve your corporate quality procedures and policies by incorporating our template(s) and tools.  It includes a fully editable template from the Bronze option, plus training, exams, and a training certificate for each assistant.  Request a quote now.

Gold Option. We Can Create Customized Quality Procedures.

One of our expert(s) will create and prepare your customized SOPs with the inputs and specific information of your company. It includes a fully editable template from the Bronze option, plus online support in document creation, implementation, and training. Request a quote online.

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REFERENCES: Short Orders.





Picture of Ramon Cayuela, MS, BS, Chemical Engineering

Ramon Cayuela, MS, BS, Chemical Engineering

CIQA President and CEO.
I've been working in validation engineering since 1992 with many multinational pharmaceutical companies. I love sharing my passion and knowledge with others. If you have any questions about anything (or just have general questions). I will be more than happy to assist you. You can count on the BEST customer service on CIQA. I go to great lengths to make sure my clients are 100% satisfied with their purchases and check emails/messages consistently throughout the day. You can rest assured that everything being sold here is as-described or your money back. I look forward to working with you!