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Cache Planning & Inventory Architecture
Floor levels, T-card color system, physical setup, and the FIFO rotation discipline.
A cache that has never been audited against a real consumption rate is not a supply plan — it is a guess. This module produces a structured, categorized, T-card-tracked group cache that any member can navigate in under 60 seconds.
The 48-hour standard. Pre-position before you need it.
3.1 The 48-hour standard and scenario tiers
Every function in the group must be able to operate for the first 48 hours of any activation without resupply. Set distinct floor levels for three scenario tiers:
- Tier 1: 72-hour event (short-duration, local disruption). Start fully stocked here.
- Tier 2: 2-week event (extended disruption, partial infrastructure loss). Work toward this.
- Tier 3: 30-day event (major infrastructure loss, no external resupply). Plan this on paper; close the gap each audit.
3.2 Item categories and how each is tracked
| Category | Definition | Tracking method | Cost of an untracked loss |
|---|---|---|---|
| Consumable | Single-use or used to depletion. Not tracked by serial number. | Quantity on hand vs. floor level. Reorder trigger set above zero. | Unknown consumption rate. Stock appears adequate, runs out unexpectedly. |
| Durable | Reusable. Tracked by category and quantity, not serial number. | Issue log with expected return date. Inspect on return. | Item not returned. Nobody knows who last had it. |
| Accountable | High-value or uniquely identifiable. Tracked by individual serial/property number. | T-card per item. Signed issue log. Card audited daily on activation. | Radio or generator unaccounted at activation. Readiness failure. |
3.3 T-cards: physical tracking for accountable items
A T-card is a physical index card — one per accountable item — stored in a visible rack. It shows the status of every high-value item at a glance without any technology. The system works during a power outage, during activation, and when the spreadsheet is unavailable.
The name comes from ICS Form 219, used by incident logistics personnel on large-scale emergencies. The principle is identical: one card per item, updated every time the item moves, audited on a schedule. Form-fillable PDF templates and a full color reference are on the T-Card Templates page. Pre-printed cards are available from IMT Gear.
| Status | Meaning |
|---|---|
| IN CACHE | Item is in its designated storage location, verified present and serviceable. |
| CHECKED OUT | Issued to a member. Record: member name, date out, expected return date. |
| OUT FOR SERVICE | Being repaired or maintained. Record: where, expected return, who authorized. |
| LOST / DAMAGED | Unserviceable or cannot be located. Record: circumstances, date, replacement priority. |
No accountable item leaves the cache without a T-card update. No exceptions. Review the full rack weekly in normal operations (2 minutes). Review daily during activation. The companion Excel workbook tracks consumables digitally. T-cards track accountable items physically. When the two disagree, the card rack is the ground truth.
3.3a T-card color coding — asset categories
Standard ICS-219 T-cards are commercially available in multiple colors. The MAG system repurposes the ICS color family for asset categories. Use gray header cards to label each rack section. Download MAG logistics form-fillable T-card PDFs: T-Card Templates. Purchase pre-printed cards: IMT Gear — ICS-219 T-Cards & Racks.
| Color | Category | Examples |
|---|---|---|
| Gray | Header / Section Divider | Rack labels only: “COMMS,” “POWER,” “MEDICAL” etc. |
| Orange | Engine / Motor Assets | Generators, pumps, chainsaws, pressure washers, compressors |
| Yellow | Powered Tools & Electrical | Inverters, battery banks, solar controllers, electric/battery power tools, portable lighting |
| Blue | Communications & Radio | All radios by serial number, base stations, repeaters, antennas, GMRS/ham gear, Meshtastic nodes, satellite devices |
| Rose | Medical Equipment | Trauma kits (numbered by ID), stretcher/litter, AED, oxygen kit, splint sets, pulse oximeters |
| Green | Hand Tools & Non-Powered | Axes, shovels, pry bars, manual pumps, block-and-tackle, ropes, hand saws, manual winches |
| Purple | Shelter, Structure & Sanitation | Large/numbered tarps, tents, portable toilets, water storage tanks, decon equipment, field tables |
| Tan | Vehicles, Trailers & Transport | Group-owned vehicles, trailers, ATVs, boats — anything that moves people or cargo as a group asset |
3.4 Cache organization by function
| Function | Core items | Notes | Accountable? |
|---|---|---|---|
| Medical | Stop-the-Bleed kits, trauma dressings, tourniquets, splints, meds, litter/stretcher | Medical lead co-manages. Rotation dates mandatory. | Yes — kits by ID (rose cards) |
| Communications | Radios, spare batteries by type, antennas, coax, power cables, programming cable | Comms lead maintains parallel inventory. Batteries tested monthly. | Yes — all radios by serial (blue cards) |
| Power / Mechanical | Generator, fuel (rotated), solar controllers, battery banks, inverters, fuses, tools | Fuel rotation logged with date and stabilizer mix ratio. | Yes — generator, battery bank (orange/yellow cards) |
| Food / Water | Shelf-stable food by tier, water storage, filtration + treatment, cooking equipment | Rotation dates mandatory. See Module 5 for food planning detail. | Filtration systems (purple cards) |
| Security | Optics, area and perimeter lighting, signage, first aid for security positions | Location held separately per Section 7 compartmentalization tiers. | Optics by serial (green/yellow cards) |
| Construction / Repair | Tarps, cordage, hand tools, fasteners, weatherproofing materials | Salvage lead coordinates with logistics lead on recovery items. | Power tools (yellow cards) |
| General / Admin | Paper, maps, compass, batteries (general), personal PPE | Often first to deplete. Maintain a generous floor. | Maps/compass if tracked |
3.5 Physical cache setup rules
- Designated receiving and issue points. Never the same location during activation.
- Security and access control. Physical locks. Access restricted to logistics lead and alternates per Section 7.
- Safety. Fuel stored separately from food and medical. Spill containment. Fire extinguisher within reach of fuel area.
- Separation of consumables and accountables. Do not co-mingle bulk stock with serialized items.
- Labeling. Every area labeled with functional category and item list. Printed labels only — handwriting fades.
- Layout for navigation. A member who has never been to the cache orients in under 60 seconds. Post a layout diagram inside the cache entrance.
3.6 Floor level calculation
| Item | Unit | Per person/day | 72-hr (10 ppl) | 14-day (10 ppl) | Notes |
|---|---|---|---|---|---|
| Drinking water | gal | 1 gal | 30 gal | 140 gal | Minimum |
| Total water (incl. sanitation) | gal | 3 gal | 90 gal | 420 gal | Per FEMA standard |
| Calories (shelf-stable) | cal | 2,000 | 60,000 | 280,000 | Sedentary min; increase for labor |
| AA batteries | units | ~2 | 60 | 280 | Varies by equipment |
| Generator fuel | gal | varies | 15–30 gal | 70–140 gal | Depends on runtime and load |
| Cooking fuel | gal/lb | varies | calculate | calculate | Depends on cooking method |
3.7 Rotation: FIFO and why it matters
FIFO (First In, First Out): the item in storage the longest is used first. New stock goes to the back. Old stock comes out first. This is the only method that prevents expiration from accumulating invisibly.
- When new stock arrives, move existing stock forward and place new stock behind it.
- Mark every consumable with the date placed in storage, not just the manufacturer expiration date.
- At monthly walkthrough, pull any item within 90 days of expiration into rotation — use it, replace with fresh stock.
- Fuel: rotate every 6 months untreated, every 12–18 months treated. Log the stabilizer date.
- Medications: follow the medical lead’s rotation protocol. Expiration is a medical judgment, not a logistics one.
Organize by function. Set floors from real numbers. T-card every accountable item.
The drill below combines classroom prep with a physical cache walkthrough. Every accountable item leaves the audit session with a T-card. Every consumable leaves with a documented floor level and a reorder trigger.
Full Cache Audit — 3–4 Hours Physical
Step 1 (40 min): List every item. Categorize each as C/D/A. Flag any whose type has not been agreed.
Step 2 (30 min): Calculate duration covered for each consumable. Compare against floor levels.
Step 3 (30 min): Inspect. Expiration dates on perishables. Condition of durables. Verify all accountable items present with current T-cards.
Step 4 (20 min): Issue T-cards for any accountable item that doesn’t have one. Fill in category/color, serial number, owner/donor, disposition.
Step 5 (30 min): Produce the gap summary. Priority reorder list with assigned responsibility and target date.
↓ Download all forms PDF
↓ T-Card templates PDF
| Variable | Our number | Notes / source |
|---|---|---|
| Total member count (adults) | Section 3 roster | |
| Dependent count (children / elderly / medical) | Section 3 roster | |
| Total planning population (sum) | ||
| Primary scenario duration tier [ 72hr / 2wk / 30d ] | Section 2 of MAG Workbook | |
| Secondary scenario duration tier [ 72hr / 2wk / 30d ] |
The floor is the minimum on-hand quantity that triggers a reorder. Set it above zero — account for lead time.
| Item | Unit | Per person/day | 72-hr floor | 14-day floor | Current stock | Gap |
|---|---|---|---|---|---|---|
| Drinking water | gal | 1 gal | ||||
| Total water (incl. sanitation) | gal | 3 gal | ||||
| Calories (shelf-stable food) | cal | 2,000 | ||||
| Generator fuel | gal | varies | ||||
| Cooking fuel | gal/lb | varies | ||||
| AA batteries | units | ~2 | ||||
| Medical expendables (basic) | ||||||
| Item / Category | C/D/A | Qty on hand | Floor level | Expiry / condition | Status / notes |
|---|---|---|---|---|---|
| Item | Gap quantity | Source (1–5 hierarchy) | Assigned to | Priority | Target date |
|---|---|---|---|---|---|
Current status — circle one:
□ IN CACHE □ CHECKED OUT □ OUT FOR SERVICE □ LOST / DAMAGED
| Date out | Issued to | Purpose / location | Date returned | Condition on return | Initials |
|---|---|---|---|---|---|
Disposition codes: G = gift | L = loan | GP = group-purchased | CO = co-owned (terms noted)
| Card # | Item / Make / Model | Serial # | Owner / Donor | Disp. | Repl. value | Location / notes |
|---|---|---|---|---|---|---|
| Card # | Item / Make / Model | Serial # | Owner / Donor | Disp. | Repl. value | Location / notes |
|---|---|---|---|---|---|---|
| Card # | Item / Make / Model | Serial # | Owner / Donor | Disp. | Repl. value | Location / notes |
|---|---|---|---|---|---|---|
| Card # | Item / Make / Model | Serial # | Owner / Donor | Disp. | Repl. value | Location / notes |
|---|---|---|---|---|---|---|
| Card # | Item / Make / Model | Serial # | Owner / Donor | Disp. | Repl. value | Location / notes |
|---|---|---|---|---|---|---|
| Card # | Item / Make / Model | Serial # | Owner / Donor | Disp. | Repl. value | Location / notes |
|---|---|---|---|---|---|---|
| Card # | Item / Make / Model / Year | VIN / Plate | Owner / Donor | Disp. | Repl. value | Location / notes |
|---|---|---|---|---|---|---|
| Card # | Asset name | Date / time out | Issued to | Deployment purpose / location | Date / time returned | Initials |
|---|---|---|---|---|---|---|
Use for any item where defaults don’t fully apply: conditional loans, co-ownership, gifts with use restrictions. Codes: G = gift | L = loan | GP = group-purchased | CO = co-owned
| Card # | Item name | Owner / Donor | Code | Specific conditions or departure terms | Donor signature | Date agreed |
|---|---|---|---|---|---|---|
Items no one remembers acquiring. Expired stock passively ignored. Accountable items checked out informally and never logged. Items stored in multiple locations with no central record. These are normal first-audit findings. The audit’s job is to surface them, not judge them.