Footwear Inventory Management & Production Planning Software

01 / The Problem - Factory Floor

■ The Problem

Your shoe factory
runs on
disconnected stages.

One style in twelve sizes with three colour options means thirty-six SKUs before you count width fittings. Leather yield varies by hide. Outsole deliveries arrive late with no early warning. Cutting, stitching, lasting, and finishing operate as silos with no shared material view.

FalOrb was built for the multi-stage complexity of footwear - where a delayed outsole delivery stalls the entire finishing line.

Pain 01

Size-Run BOM Complexity

Every style multiplied by size, colour, and width creates massive BOM trees. Material requirements differ by size. No automated scaling from sample BOM to full size-run production BOM.

Pain 02

Material Yield Uncertainty

Leather and textile yields vary by batch and supplier. Cutting plans based on assumed yields, not actuals. Material shortfalls discovered mid-production when hides don't stretch as far as planned.

Pain 03

Multi-Stage Blind Spots

Cutting, stitching, lasting, and finishing operate independently. No visibility into work-in-progress between stages. Bottlenecks at lasting discovered when stitched uppers pile up with nowhere to go.

Pain 04

Seasonal Demand Pressure

Retail buyers place orders months ahead with rigid delivery windows. Production capacity allocated without confirming material availability. Late deliveries mean cancelled orders and lost shelf space.

02 / The Platform - Built for Footwear Manufacturing

■ The Platform

One system from
raw leather to
boxed pair.

FalOrb covers the full footwear manufacturing lifecycle. Size-run BOM management, material yield tracking, multi-stage production orders, and procurement planning - all connected in a single platform.

Every hide is tracked. Every cut is recorded. Every stage handoff is visible. From raw material receipt through cutting, stitching, lasting, and finishing to packed and dispatched footwear.

■ Platform in Action

See what your
footwear manufacturing operations
look like inside FalOrb.

Real screens. Real layout. Simulated data from a footwear manufacturing 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

Total Locations

Critical Items

Pending Transfers

Active Alerts

Manufacturing

Active Production Orders

Material Shortages

Products ATP Zero

MRP Shortfalls

Network

Cutting & Stitching Floor

Production

Healthy

3 critical 13 low 245 healthy

Lasting & Sole Attachment

Production

Low

5 critical 21 low 178 healthy

Raw Materials Warehouse

Warehouse

Healthy

2 critical 18 low 412 healthy

Finished Goods Distribution

Distribution

Healthy

22 low 634 healthy 41 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

All 15

Draft 2

Confirmed 3

In Progress 6

Completed 3

Order #	Product	Location	Qty Ordered	Qty Produced	Material	Status
PO-2026-1401	Men's Running Shoe (Sizes 7-13)	Lasting & Sole Attachment	18,000	12,600	Sufficient	In Progress
PO-2026-1402	Women's Leather Chelsea Boot	Cutting & Stitching Floor	6,000	6,000	Sufficient	Completed
PO-2026-1403	Children's Canvas Sneaker (Sizes 1-6)	Cutting & Stitching Floor	24,000	9,400	Partial	In Progress
PO-2026-1404	Industrial Safety Boot (Steel Toe)	Lasting & Sole Attachment	4,500	0	Critical	Confirmed
PO-2026-1405	Women's Wedge Sandal (Summer '27)	Cutting & Stitching Floor	10,000	0	Sufficient	Draft

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

All 12

Active 8

Acknowledged 3

Resolved 1

	Type	Item	Location	Message	Triggered	Status
▲	Material Shortage	EVA Foam Midsole Blanks (Size 10)	Lasting & Sole Attachment	Zero stock across all size runs - 2 lines stopped	3 min ago	Active
▼	Size Ratio Imbalance	Mesh Upper Fabric (Navy)	Raw Materials Warehouse	Sufficient for sizes 7-10 but short on 11-13 by 1,400 pairs	20 min ago	Acknowledged
▲	Low Stock	Rubber Outsoles (TR Compound)	Lasting & Sole Attachment	280 pairs remaining - daily consumption is 900 pairs	55 min ago	Active
▼	Quality Reject	Full Grain Leather Hides (Tan)	Cutting & Stitching Floor	12% reject rate on lot #LH-3380 - surface blemishes above tolerance	3 hr ago	Acknowledged
●	Stock Normalized	Shoe Laces (Flat, 120cm)	Raw Materials Warehouse	Received 50,000 units - all color variants back in stock	6 hr ago	Resolved

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.

Detect

Stock health reclassified in real-time. Four-state system flags the risk level before it becomes a problem.

Alert

The right role receives the alert. 13 alert types ensure the signal reaches the person who can act.

Act

Transfer request routed. MRP recommendation generated. Production order adjusted. Structured workflow, not ad hoc chat.

Record

Every action logged to the immutable audit ledger. Full traceability from detection to resolution.

The control
tower for your
footwear
production floor.

Your shoe factory
runs on
disconnected stages.

Inventory & Production

Supply Chain & Operations

One system from
raw leather to
boxed pair.

See what your
footwear manufacturing operations
look like inside FalOrb.

Operations Dashboard

Overview

Production Orders

Production Orders

13-Type Alert System

Alerts

From stockout
to signal in
under a second.

Your factory floor
deserves visibility.

The controltower for yourfootwearproduction floor.

Your shoe factoryruns ondisconnected stages.

Inventory & Production

Supply Chain & Operations

One system fromraw leather toboxed pair.

See what yourfootwear manufacturing operationslook like inside FalOrb.

Operations Dashboard

Overview

Production Orders

Production Orders

13-Type Alert System

Alerts

From stockoutto signal inunder a second.

Your factory floordeserves visibility.

The control
tower for your
footwear
production floor.

Your shoe factory
runs on
disconnected stages.

One system from
raw leather to
boxed pair.

See what your
footwear manufacturing operations
look like inside FalOrb.

From stockout
to signal in
under a second.

Your factory floor
deserves visibility.