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Inventory & Production Management for Consumer Durables

The control
tower for your
appliance
assembly line.

Complex assemblies, multi-tier BOMs, and warranty-driven traceability. FalOrb gives consumer durables manufacturers real-time visibility into component stock, assembly readiness, and production progress across every line.

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Real-Time StockMulti-Level BOMATP EngineMRP PlanningAssembly TrackingSupplier ManagementTransfer EngineAudit LedgerReal-Time StockMulti-Level BOMATP EngineMRP PlanningAssembly TrackingSupplier ManagementTransfer EngineAudit Ledger
Consumer Durables and Home Appliances operations
01 / The Problem - Assembly Floor
■ The Problem

Your assembly line
runs on
outdated stock data.

Hundreds of components per appliance with stock data that's hours or days old. BOM changes from engineering don't reach procurement. When a key component is short, the line stops and rework begins.

FalOrb was built for the assembly complexity of consumer durables - where component availability determines throughput and warranty traceability is a long-term obligation.

Pain 01
Assembly BOM Depth
Multi-level BOMs with hundreds of components per product. Sub-assembly requirements not linked to component stock. Shortages discovered at the line instead of in planning. Rework costs mount.
Pain 02
Demand Forecasting Gaps
Seasonal demand and promotional cycles with no forward material planning. Components ordered reactively. Production scheduled without confirming material availability. Customer delivery dates missed.
Pain 03
Warranty & Traceability
Component-to-product traceability required for warranty claims and recalls. Serial number and batch tracking maintained manually. Warranty investigations require manual record reconstruction.
Pain 04
Multi-Model Line Complexity
Multiple product models sharing the same production lines. Changeover scheduling and material kitting done manually. Component allocation across models based on memory, not system data.
Consumer Durables and Home Appliances production

Inventory & Production

Real-Time Stock / Multi-Level BOM / Auto-Costing

Supply chain operations

Supply Chain & Operations

MRP Horizons / Supplier Management / Alert System

Consumer Durables and Home Appliances platform
02 / The Platform - Built for Consumer Durables and Home Appliances
■ The Platform

One system from
component to
boxed appliance.

FalOrb covers the full consumer durables lifecycle. Multi-level BOM management, component tracking, production order management, and procurement planning - all connected with real-time stock visibility.

Every component movement is recorded. Every assembly is traceable. Every stock level is live. From component receipt through sub-assembly and final assembly to finished goods dispatch.

■ Platform in Action

See what your
consumer durables and home appliances operations
look like inside FalOrb.

Real screens. Real layout. Simulated data from a consumer durables and home appliances facility.

01 / Overview

Operations Dashboard

One screen to see every location, every critical item, every in-transit shipment. Health status propagates from stock to location to the organization level.

falorb.com/overview

Overview

Updated just now
Refresh
7
Total Locations
3
Critical Items
8
Pending Transfers
13
Active Alerts
Manufacturing
16
Active Production Orders
2
Material Shortages
1
Products ATP Zero
5
MRP Shortfalls
Network
Assembly Plant - Midwest
Production
Healthy
2 critical 14 low 312 healthy
Component Warehouse
Warehouse
Low
6 critical 24 low 278 healthy
Appliance Testing Facility
Production
Healthy
3 low 145 healthy
Regional Distribution Center
Distribution
Healthy
11 low 267 healthy 22 surplus
02 / Production

Production Orders

Full lifecycle tracking from draft to completion. Material status tells you instantly whether the line can run or needs procurement action.

falorb.com/production-orders

Production Orders

+ New Order
All 16
Draft 2
Confirmed 3
In Progress 6
Completed 3
Order #ProductLocationQty OrderedQty ProducedMaterialStatus
PO-2026-6201Smart Washing Machine 10kgAssembly Plant - Midwest2,4001,680SufficientIn Progress
PO-2026-6202Inverter Split AC 1.5 TonAssembly Plant - Midwest3,6003,600SufficientCompleted
PO-2026-6203Convection Microwave Oven 32LAppliance Testing Facility5,0002,100PartialIn Progress
PO-2026-6204Brushless Motor Vacuum CleanerAssembly Plant - Midwest8,0000CriticalConfirmed
PO-2026-6205Side-by-Side Refrigerator 680LAssembly Plant - Midwest1,2000SufficientDraft
03 / Alerts

13-Type Alert System

Auto-generated, role-routed alerts with one-click acknowledge and resolve. The system detects, you act.

falorb.com/alerts

Alerts

All 13
Active 8
Acknowledged 3
Resolved 1
TypeItemLocationMessageTriggeredStatus
▲Material ShortageBLDC Compressor UnitsComponent WarehouseZero stock - 2 refrigerator lines idle awaiting resupply8 min agoActive
▼Low StockPCB Control Boards (v4.2)Component Warehouse42 units remaining, 1,200 needed for current production run30 min agoAcknowledged
▲Quality HoldStainless Steel Drum AssembliesAssembly Plant - MidwestDimensional variance on lot #SD-7790 - 300 units quarantined1 hr agoActive
▼Transfer DelayedTempered Glass ShelvesRegional Distribution CenterShipment from supplier stuck in customs clearance4 hr agoAcknowledged
●Stock ReplenishedCopper Tubing (6mm)Component WarehouseReceived 8,000m from primary supplier - stock normalized7 hr agoResolved
Module 01
Location Management
Every plant, warehouse, and zone mapped. Multi-site hierarchy with role-based access control across your entire operation.
Module 02
Item & BOM
Multi-level bill of materials with auto-costing. Component tracking from raw input to final assembly with full version control.
Module 03
Production Orders
Material reservation, real-time progress, and variance tracking across every production run. Full lifecycle visibility from creation to completion.
Module 04
ATP Engine
Available-to-promise. Know what you can make and when, before committing to delivery. Real-time calculation against live stock and reservations.
Module 05
Transfer Engine
Structured inter-location transfers. Request, approve, ship, receive - every step recorded in the ledger with full chain of custody.
Module 06
MRP & Procurement
Demand planning across 7, 14, 30, and 60-day horizons. Purchase order lifecycle and supplier management with automated recommendations.
Module 07
Alert System
13 alert types with auto-resolve capability. Role-routed by severity to ensure the signal reaches the person who can act - immediately.
Module 08
Audit Ledger
Immutable. Every movement, every adjustment, every transaction recorded permanently. Nothing is mutated directly. The single source of truth.
■ How It Works

From stockout
to signal in
under a second.

When a critical material drops below threshold, FalOrb doesn't wait for someone to notice. The system detects, alerts, acts, and records - automatically.

01
Detect
Stock health reclassified in real-time. Four-state system flags the risk level before it becomes a problem.
02
Alert
The right role receives the alert. 13 alert types ensure the signal reaches the person who can act.
03
Act
Transfer request routed. MRP recommendation generated. Production order adjusted. Structured workflow, not ad hoc chat.
04
Record
Every action logged to the immutable audit ledger. Full traceability from detection to resolution.
“
Designed on the factory floor, not in a software lab. Every feature exists because a manufacturer needed it. Not because a product manager imagined it.
- FalOrb, Product Philosophy
8
Core Platform Modules
13
Alert Types / Auto-Resolve
60d
MRP Planning Horizon
4
Stock Health States

Your assembly line
deserves real-time data.

FalOrb is built for consumer durables manufacturers where component availability drives throughput and warranty traceability is a decade-long commitment. If that's your operation, let us show you what connected assembly management looks like.

Book a Demo →
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