Inventory control with real-time operational context.
Track receipts, issues, returns, transfers, and replenishment so stores and production teams can trust material availability.
Warehouse Stores Control
Track material receipts, locations, cycle counts, and reorder alerts in real-time.
Scan receipts & issues
Use mobile scanner apps to check material in and out of storage.
Improvement: Closes inventory gaps.
Real-time Stock Levels
Monitor stock levels, set reorder points, and auto-notify buyer teams.
Improvement: Prevents line stoppages.
Batch & Lot Tracking
Link material lots to manufacturing runs for full downstream tracking.
Improvement: Secures batch recalls.
Stores Audits
Standardize inventory audits with structured cycle-counting checks.
Improvement: Keeps balance books clean.
Inventory Digital Center
Provide stores and warehouse teams with a live operational view. Track physical counts, reserved batch stocks, safety thresholds, and bin locations in real-time.
Live Stock Balances
Monitor on-hand quantities, pending allocations, and reorder levels.
Bin Location Mapping
Instantly trace inventory coordinates down to specific racks, zones, and bins.
Replenishment Flags
Alert teams dynamically when available stock drops below reorder points.
SKU-4471: Steel Fasteners M8
Warehouse Location: Rack B, Bin 12
6-Step Inventory Workflow
Manage the physical stock lifecycle from dock receipt to workstation issue and automatic purchase releases.
Receipt
Material check-in
Log incoming supplier parts, capture quantities, check packing lists against active POs, and generate tracking lot codes.
Log Stock Discrepancy
Record variations between system ledger quantities and physical shelf audits. Tie each deviation directly to a bin location, SKU, and operational cause.
Physical Count Entry
Enable store teams to log physical counts directly from bins.
Variance Calculation
Instantly calculate negative or positive variance logs.
Standard Cause Trees
Categorize discrepancies under scrap, unlogged transfers, or damage.
Ledger Adjustment Requests
Flag ledger corrections for shift supervisor approval.
Discrepancy Log
DIS-2026-904-250 units
Variance Logged14,200 units
System CountStores Shortage Root Cause Analysis
RCA-INV-104Shortage Pattern Finding
Anomaly: Fastener SKU-4471 on-hand quantities persistently drift negative (-2.3% variance average) during shift runs.
Analysis: Cross-referencing logs with downtime alerts tags 92% of the variance directly to the Line 4 conveyor double-feeds (parts scrapped on floor and swept away without scrap logging tags).
Task: Add visual scrap entry button to Line 4 terminal. Enable operators to record floor scraps instantly without leaving the station.
Shortage & Discrepancy Analysis
Isolate physical stores leaks and trace recurring count variance. Correlate cycle adjustments with assembly run scrap records to maintain audit logs.
Physical Drift Tracking
Monitor negative count drifts to pinpoint where scrap leakage occurs.
Line-Side Correlation
Correlate workstation issues with unlogged material drops.
CAPA Action Pushes
Dispatch warning tickets to tooling leads for vibrating feeders.
Audit Log Compliance
Provide fully compliant records of physical ledger updates.
Supported Inventory Scenarios
Bridge physical warehouses with line-side inventories. Track every category of raw, WIP, and consumable stock.
Raw Materials
Manage bulk receipts, lot coordinate tracking, and direct supplier material verification programs.
Work-in-Progress (WIP)
Track semi-finished assemblies, batches awaiting curing, and reconcile counts across workstations.
Finished Goods
Verify final packaging counts, log dispatch receipts, and update corporate inventories automatically.
Consumables & Spares
Monitor tooling inserts, lubricants, machine spare parts, and enforce safety stock reorders.
Connected Inventory Hub
Unify warehousing telemetry with procurement and planning ledgers.
ERP Integrations
Post material receipts, issues, and counts directly to SAP, NetSuite, or Dynamics in real-time.
Production Scheduling
Reserve components automatically based on scheduled production requirements and BOM limits.
Quality Holds
Block out-of-spec incoming batches or failed inspection lots from being issued to workstations.
Automated Purchasing
Trigger replenishment orders or RFQs to approved suppliers when stock drops below safety levels.
Numbers from real engagements.
Give teams one view of what is on hand and where it is.
Make shortages and replenishment needs visible earlier.
Maintain an accountable history from receipt through issue or return.
Built for teams that need this to just work.
Who this is for
- Warehouse Stores Teams tracking physical receipts, issues, transfers, and counts.
- Production Planners needing reliable material availability forecasts and BOM allocation rules.
- Manufacturers currently reconciling inventory from spreadsheets or manual physical counts.
The operational building blocks your team needs.
Track inventory transactions at storage bins, configure safety limits, manage quality holds, and verify stock balances dynamically.
Movement tracking
Record every receipt, issue, return, transfer, and adjustment against the right material and location.
Stock visibility
Make current stock, reservations, and replenishment needs visible to authorised teams.
Material traceability
Connect material movements with lots, jobs, inspection status, and downstream consumption.
From the shop floor to the leadership view.
Enforce real-time transactions, route count adjustments to supervisors, and connect with enterprise databases.
Material Receipts
Log incoming supplier packing lists against open PO numbers instantly.
Bin Coordinates Mapping
Map materials to specific racks, zones, and bins with digital scan confirmations.
Production Allocation
Reserve components dynamically for scheduled job runs, locking raw stock.
Offline Terminal Logs
Cache count updates locally on devices when plant network drops.
Variance Adjustments
Flag physical count discrepancies for immediate supervisor sign-offs.
Purchase Pushes
Trigger corporate ERP procurement drafts automatically on low stock levels.
A repeatable path, every time.
1. Map Bin Layouts (Weeks 1-2)
Set up storage locations, zones, rack coordinates, and sync the material catalog.
2. Configure Safety Levels (Weeks 3-4)
Define safety stock limits, reorder thresholds, and validation rule boundaries.
3. Deploy Stores Terminals (Weeks 5-6)
Install handheld cycle count apps and line-side issue tablets for operators.
4. Scale Enterprise Sync (Weeks 7-8)
Connect material transaction logs with scheduling, purchasing, and ERP systems.
Industrial technology your operation can rely on.
We combine industrial data, connected workflows, and secure integrations to make this solution practical for real plant operations.
Inventory Ledgers
Ingestion and dispatch logs
Location Mapping
Bin coordinate mapping
Lot Tracking Engine
Raw lot traceability
The questions we hear most.
Can this track multiple warehouse locations?+
Yes. The platform supports multi-warehouse, multi-plant staging configurations. You can track stocks across main stores, line-side inventories, and transit locations.
How does batch or lot tracking work?+
Every receipt generates or maps a batch/lot ID. This lot number follows the material through reservations, staging, consumption, and finished goods, providing complete traceability.
Can operators log transactions offline?+
Yes. Our floor terminals cache issues, cycle counts, and transfers locally if the warehouse network drops, then upload the logs to the master ledger once reconnected.
How does this sync with our ERP for purchasing and replenishment?+
Transactions are posted in real-time to ERP ledgers (SAP, NetSuite) via secure REST API protocols. When stock drops below reorder points, the system alerts procurement or posts draft purchase requisitions directly.
Most engagements span more than one practice.
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