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MAG Training Module 3


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Logistics & Supply Training › Module 03 of 06
Module 03 of 06

Cache Planning & Inventory Architecture

Floor levels, T-card color system, physical setup, and the FIFO rotation discipline.

Format: Classroom + physicalDuration: 3–4 hrsIncludes audit exercisePrereq: Module 02 complete
Bottom Line Up Front

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 Concept

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.
The cardinal rule
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.

The Application

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.

The Drill

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

Module 03 Worksheet — Group Size & Planning Baseline

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 ]
Module 03 Worksheet — Consumable Floor Level Calculator

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)
Module 03 Worksheet — Cache Audit Record (C = Consumable | D = Durable | A = Accountable)

Item / Category C/D/A Qty on hand Floor level Expiry / condition Status / notes
Module 03 Worksheet — Gap Summary & Reorder List

Item Gap quantity Source (1–5 hierarchy) Assigned to Priority Target date
A.2 — T-Card Template — copy onto 4×6 index card, one per accountable item

FRONT — Identification & Status

Current status — circle one:

□ IN CACHE    □ CHECKED OUT    □ OUT FOR SERVICE    □ LOST / DAMAGED

REVERSE — Deployment Log
Date out Issued to Purpose / location Date returned Condition on return Initials
A.2a — Non-Consumable Asset Register — one table per T-card color category

Disposition codes: G = gift  |  L = loan  |  GP = group-purchased  |  CO = co-owned (terms noted)

Orange — Engine / Motor Assets
Card # Item / Make / Model Serial # Owner / Donor Disp. Repl. value Location / notes
Yellow — Powered Tools & Electrical
Card # Item / Make / Model Serial # Owner / Donor Disp. Repl. value Location / notes
Blue — Communications & Radio Equipment
Card # Item / Make / Model Serial # Owner / Donor Disp. Repl. value Location / notes
Rose — Medical Equipment
Card # Item / Make / Model Serial # Owner / Donor Disp. Repl. value Location / notes
Green — Hand Tools & Non-Powered
Card # Item / Make / Model Serial # Owner / Donor Disp. Repl. value Location / notes
Purple — Shelter, Structure & Sanitation
Card # Item / Make / Model Serial # Owner / Donor Disp. Repl. value Location / notes
Tan — Vehicles, Trailers & Transport
Card # Item / Make / Model / Year VIN / Plate Owner / Donor Disp. Repl. value Location / notes
A.2b — Asset Deployment Log — permanent record of every asset deployment

Card # Asset name Date / time out Issued to Deployment purpose / location Date / time returned Initials
A.2c — Item-Level Disposition Agreements — for items with non-standard terms

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
What a good audit reveals
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.

← Module 02: Ownership & Cost-Sharing
Module 04: Needs, Acquisition & Receiving →
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  • The Next of Kin Workbook - Patreon The Next of Kin Workbook - Patreon $23.95
  • Personal Preparedness Assessment Report Personal Preparedness Assessment Report $179.95
  • Bundle - Family Emergency Plan + Next of Kin Workbooks Bundle - Family Emergency Plan + Next of Kin Workbooks $49.95
  • The Next of Kin Workbook The Next of Kin Workbook $29.95
  • ASAR — 50 Mile Radius ASAR — 50 Mile Radius $139.95
  • ASAR 50-MILE + FEP WORKBOOK ASAR 50-MILE + FEP WORKBOOK $169.95
  • ASAR — 50 Mile Radius - Patreon ASAR — 50 Mile Radius - Patreon $39.95
  • Bundle - The Series Starter (Paperback) Bundle - The Series Starter (Paperback) $29.98
  • The Brush (Paperback) The Brush (Paperback) $15.99
  • The Meadow Protocol (Paperback) The Meadow Protocol (Paperback) $13.99
  • Cards (4x6) - Brevity Cards for OTP Cards (4x6) - Brevity Cards for OTP $24.95
  • Communications Card bundle (13 cards) Communications Card bundle (13 cards) $41.95
  • Personal Preparedness Assessment Workbook Personal Preparedness Assessment Workbook $24.95
  • Family Emergency Plan Workbook Family Emergency Plan Workbook $24.95

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