Case study · Inventory
Inventory Management System for a Manufacturing MSME
A confidential manufacturing MSME improved book-versus-physical stock reconciliation with a custom inventory system — real-time raw, WIP and finished-goods tracking, FIFO, reorder alerts and consumption tied to work orders.
The business challenge
Book stock and physical stock no longer agreed
Stock was tracked in registers and spreadsheets, so recorded quantities steadily drifted from what was actually on the racks. The result was surprise shortages that stopped lines, rushed premium buying, and working capital tied up in slow-moving excess.
With consumption against work orders untracked, usage and variance were largely a matter of guesswork, and physical stock-takes were slow and hard to reconcile.
Operational impact — before Edhaas
What the team lived with day to day
Stock mismatch
Recorded and physical quantities frequently disagreed.
Line stoppages
Surprise shortages halted production and forced premium buying.
Excess capital
Over-ordering locked money in slow-moving stock.
Slow stock-takes
Manual counts were infrequent and hard to reconcile.
What Edhaas built
An inventory system shaped to their stores
Edhaas built the system around the MSME's materials, locations and consumption patterns.
Real-time stock by location
Live balances for raw, WIP and finished goods across stores and bins.
GRN, issue & return tracking
Every movement recorded against the right document.
FIFO & batch control
Older and correct batches consumed first.
Min-max reorder alerts
Automatic alerts and requisitions at reorder level.
Consumption vs work order
Material issue tied to production for clear usage and variance.
Barcode stock-takes
Faster, more accurate physical counts.
Workflow covered
Every movement recorded, every balance easier to verify
- 1Goods Receipt (GRN)
- 2Stores & Binning
- 3Issue to Production
- 4WIP Tracking
- 5Finished Goods
- 6Reorder & Alerts
- 7Stock Reports
Key features
What the system does
Live stock balances
Raw, WIP and finished goods by location and bin.
Reorder alerts
Min-max triggers with optional auto-requisition.
FIFO & batch
Correct stock consumed first with lot visibility.
Consumption tracking
Issue tied to work orders for accurate usage.
Barcode counting
Fast stock-takes and easy reconciliation.
Tally / ERP friendly
Designed to integrate with existing systems.
Business outcomes
What changed after go-live
Outcomes are described qualitatively. Specific figures are kept confidential at the client's request.
Improved book-versus-physical reconciliation
Recorded stock brought back in line with the racks.
Fewer stoppages
Reorder alerts helped prevent surprise shortages.
Better visibility of excess and slow-moving stock
Reduced over-ordering and slow-moving excess.
Faster stock-takes
Barcode-based counting simplified reconciliation.
Inside the system
What the software looks like
Representative interfaces from this type of build. Actual client screens are confidential.
Related solutions
Software behind this case study
Questions
About this inventory project
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