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Question My W/R/E doesn't add up. Bars not full, but settlement reports say I'm producing more than enough.

Strikemasterice4

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Basically I should have an army based on my output of wages, ration and equipment, but the W/R/E bars are not full and I can't recruit. I'm using Soldier Needs.

I'm using Conqueror and SS-1. Playing the Minutemen factionpack as liberators. I have a few other faction packs installed for flavor.
I installed both SS and Conq early in my playthrough, I didn't start a new game or encountered Jammer's questline (already saved Preston). I am using Rise of the Commonwealth (RotC) but I'm not using prebuilt cities.

I currently have 5 guards spread across 5 outposts and 4 Vassals.
Here are the following settlement reports from the Warplanner's desk:

Oberland Station - Vassal: W=28, R=112, E=19, Civilians:16, Moral:100% Control: 0%
Tenpines Bluff - Outpost: W=0, R=60, E=0, Civilians:9 Moral:78%, Control: 0%
Graygarden - Outpost: W=0, R=60, E=40, Civilians:8 Moral:38%, Control:90% Guards:1
Sanctuary Hills - Vassal: W=103, R=154, E=84, Civilians:19, Moral:100% Control: 90% Guards: 1
Red Rocket Truck Stop - Main base: W=50, R=50, E=50, Civillians:2, Moral:100% Control: 68% (no city plan)
Abernathy Farm - Vassal: W=0, R=330, E=0, Civilians:16, Moral:100% Control: 76% Guards: 1, Workers: 1 (actually glitch, worker should be dead)
Sunshine Tidings Coop - Vassal: W=28, R=210, E=60, Civilians:10, Moral:100% Control: 76% Guards: 1
Starlight DriveIn - Outpost: W=15, R=0, E=40, Civilians:10, Moral:100% Control: 0% Guards: 1
Hangman's Alley - Outpost: W=10, R=0, E=30, Civilians:7 Moral:60% Control: 0%

Production:
Total Wages: 234
Total Rations: 976
Total Equipment: 323

Usage:
5 Guards: 10 of each resources
97 Civilians (settlers): 10 rations each

Thus total consumption should be as follows:
Wages: 50
Rations: 1020
Equipment:50

What the bars say on the bottom-right of the HUD:
Wages: Full +155
Rations: Full, no surplus
Equipment: Half-Full

This clearly isn't right. I'm definitely producing more equipment than I'm using but the bars don't reflect that.
I'm using realistic build time for plots, and I've waited for several days. I've turned Dynamic Needs off.
The bars fluctuate naturally but stay in the relatively the same ratio.

I've also never had a hostile takeover / outpost defense event happen to me at all. They do occur when I am testing the system and sleep several days in a row and I get a quest to defend them, but no enemy is there when I arrive and sometimes a random settlement with no guard will automatically get captured with the pop-up menu message. However, when I reload and continue playing as normal they never happen. I do get the vanilla settlement raids however. I've checked the MCM settings City Manager Holotape/Desk I should be getting them.

Until now, I've always needed to turn Soldier Needs off before I recruited for a raid because I could never get the bars full, even on my very first recruitment.

Could it be that the game is not updating the death of my warriors, so dead soldiers still consume resources?
 
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