Glass & Ceramics Inventory Management & Production Planning Software

Glass, Ceramics and Concrete Manufacturing operations

01 / The Problem - Plant Floor

■ The Problem

Your kiln operation
runs on
batch-by-batch uncertainty.

Furnaces that run continuously for years. Kilns with firing cycles that span days. Raw mineral quality that varies by quarry and season. When a silica delivery arrives with different iron content, the entire glass colour shifts unless the batch formula adjusts. But the lab results arrive after the batch is already mixed.

FalOrb was built for the process intensity of glass and ceramics - where raw material quality directly determines finished product quality and kiln schedules cannot pause for inventory questions.

Pain 01

Raw Mineral Quality Variability

Silica, feldspar, clay, and limestone quality varies by quarry and delivery. Chemical analysis results determine batch adjustments. No automated link between incoming mineral quality data and batch formulation parameters.

Pain 02

Continuous Furnace Operations

Glass furnaces run continuously for 10 to 15 years. Material supply must be uninterrupted. A furnace starved of batch material suffers irreversible damage. No forward visibility tool ensuring raw material supply covers continuous furnace demand.

Pain 03

Kiln Loading Optimisation

Ceramics kilns fired in batches with multi-day cycles. Kiln loading must maximise capacity utilisation. Product mix per kiln load affects firing profiles. No planning tool that optimises kiln loading against order priority and product compatibility.

Pain 04

Breakage and Yield Losses

Glass and ceramics experience breakage at multiple production stages. Yield losses vary by product type and process conditions. Scrap recorded manually and often late. No real-time yield tracking to trigger production adjustments.

Glass, Ceramics and Concrete Manufacturing platform

02 / The Platform - Built for Glass, Ceramics and Concrete Manufacturing

■ The Platform

One system from
raw mineral to
finished product.

FalOrb covers the full glass, ceramics, and concrete lifecycle. Mineral inventory with quality tracking, batch formulation management, kiln and furnace scheduling, yield monitoring, and finished goods inventory - all connected in one platform.

Every mineral delivery is analysed. Every batch is formulated. Every kiln load is tracked. From raw mineral receipt through batching, melting or firing, forming, and finishing to packed and dispatched product.

■ Platform in Action

See what your
glass, ceramics and concrete manufacturing operations
look like inside FalOrb.

Real screens. Real layout. Simulated data from a glass, ceramics and concrete 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

Float Glass Production Line

Production

Healthy

2 critical 11 low 298 healthy

Ceramics Kiln Facility

Production

Low

9 critical 26 low 215 healthy

Aggregate & Batch Plant

Production

Critical

14 critical 33 low 178 healthy

Building Products Depot

Distribution

Healthy

10 low 364 healthy 28 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-2026-9901	Low-E Insulated Glass Unit (6x8ft)	Float Glass Production Line	3,000	2,140	Sufficient	In Progress
PO-2026-9902	Porcelain Floor Tile (24x24 Polished)	Ceramics Kiln Facility	25,000	25,000	Sufficient	Completed
PO-2026-9903	Ready-Mix Concrete (5000 PSI)	Aggregate & Batch Plant	1,500	810	Partial	In Progress
PO-2026-9904	Tempered Safety Glass Panel	Float Glass Production Line	4,000	0	Critical	Confirmed
PO-2026-9905	Precast Concrete Wall Panel	Aggregate & Batch Plant	200	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 13

Active 8

Acknowledged 3

Resolved 1

	Type	Item	Location	Message	Triggered	Status
▲	Stock Out	Soda Ash (Na2CO3, Dense Grade)	Float Glass Production Line	Zero stock — glass batch formulation cannot proceed	15 min ago	Active
▲	Below Safety Stock	Portland Cement Type I/II	Aggregate & Batch Plant	Stock at 28 tons below safety level of 100 tons	1 hr ago	Active
▼	MRP Shortfall	Ball Clay (Tennessee No. 5)	Ceramics Kiln Facility	Projected shortfall of 12 tons in 3 weeks	4 hrs ago	Pending
▼	Lead Time Breach	Low-Iron Silica Sand (99.5%)	Float Glass Production Line	Supplier delivery delayed by 10 days	5 hrs ago	Pending
●	Transfer Complete	Ceramic Glaze Frit (Opaque White)	Ceramics Kiln Facility	4 tons received from Building Products Depot	8 hrs 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
glass and ceramics
production plant.

Your kiln operation
runs on
batch-by-batch uncertainty.

Inventory & Production

Supply Chain & Operations

One system from
raw mineral to
finished product.

See what your
glass, ceramics and concrete 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 kiln operation
deserves batch precision.

The controltower for yourglass and ceramicsproduction plant.

Your kiln operationruns onbatch-by-batch uncertainty.

Inventory & Production

Supply Chain & Operations

One system fromraw mineral tofinished product.

See what yourglass, ceramics and concrete manufacturing operationslook like inside FalOrb.

Operations Dashboard

Overview

Production Orders

Production Orders

13-Type Alert System

Alerts

From stockoutto signal inunder a second.

Your kiln operationdeserves batch precision.

The control
tower for your
glass and ceramics
production plant.

Your kiln operation
runs on
batch-by-batch uncertainty.

One system from
raw mineral to
finished product.

See what your
glass, ceramics and concrete manufacturing operations
look like inside FalOrb.

From stockout
to signal in
under a second.

Your kiln operation
deserves batch precision.