Hardware Manufacturing Inventory Management & Production Planning Software

01 / The Problem - Production Floor

■ The Problem

Your hardware lines
run on
SKU volume overload.

Thousands of active SKUs across screws, bolts, hinges, locks, and fittings. Each in multiple sizes, materials, and finishes. Production runs measured in millions of pieces. When a distributor order arrives for fifty SKUs, confirming stock and production capacity across all items means checking multiple systems.

FalOrb was built for the high-volume, high-SKU reality of hardware manufacturing - where a single die change produces a different product and inventory accuracy across thousands of bins determines order fulfilment.

Pain 01

Massive SKU Counts

Thousands of active SKUs with each product in multiple sizes, materials, and finishes. No single view of stock across all variants. Inventory discrepancies at the bin level multiply across the catalogue.

Pain 02

High-Volume Production Tracking

Stamping and forging lines produce millions of pieces per day. Output quantities estimated rather than counted precisely. Yield losses from die wear accumulate undetected until physical inventory counts.

Pain 03

Die and Tooling Management

Production quality depends on die condition. Die changes create production gaps. Tooling life tracked manually. No automated link between die strike counts and scheduled maintenance or replacement.

Pain 04

Finish and Plating Coordination

Raw parts move to external plating or coating vendors before returning as finished goods. Work-in-progress at outside processors invisible. Return timing uncertain. No visibility into how much WIP is at each processor.

02 / The Platform - Built for Hardware Manufacturing

■ The Platform

One system from
raw wire rod to
finished hardware.

FalOrb covers the full hardware manufacturing lifecycle. Raw material inventory, production BOM management, high-volume batch tracking, outside processing coordination, and finished goods inventory - all connected across thousands of SKUs.

Every coil is tracked. Every batch is recorded. Every outside process is monitored. From raw steel receipt through stamping, forging, machining, and finishing to binned and dispatched hardware products.

■ Platform in Action

See what your
hardware manufacturing operations
look like inside FalOrb.

Real screens. Real layout. Simulated data from a hardware 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

Fastener Production Line

Production

Healthy

1 critical 12 low 486 healthy

Lock & Hinge Assembly

Production

Healthy

4 critical 18 low 312 healthy

Wire & Rod Stockroom

Warehouse

Low

9 critical 31 low 224 healthy

Hardware Distribution Center

Distribution

Healthy

8 low 567 healthy 45 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 11

Draft 2

Confirmed 3

In Progress 6

Completed 3

Order #	Product	Location	Qty Ordered	Qty Produced	Material	Status
PO-2026-7701	Grade 8 Hex Bolt (3/4"-10 x 3")	Fastener Production Line	50,000	38,200	Sufficient	In Progress
PO-2026-7702	Mortise Deadbolt Lock Set	Lock & Hinge Assembly	4,000	4,000	Sufficient	Completed
PO-2026-7703	Heavy-Duty Gate Hinge	Lock & Hinge Assembly	8,000	5,100	Partial	In Progress
PO-2026-7704	Stainless Steel Deck Screw (#10 x 3")	Fastener Production Line	100,000	0	Sufficient	Confirmed
PO-2026-7705	Cabinet Pull Handle (Brushed Nickel)	Lock & Hinge Assembly	12,000	0	Critical	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 8

Active 8

Acknowledged 3

Resolved 1

	Type	Item	Location	Message	Triggered	Status
▲	Below Safety Stock	4140 Alloy Steel Wire Rod (8mm)	Wire & Rod Stockroom	Stock at 2.4 tons below safety level of 8 tons	40 min ago	Active
▲	Stock Out	Zinc Plating Solution (Alkaline)	Fastener Production Line	Zero stock — finishing line idle	1 hr ago	Active
▼	MRP Shortfall	Brass Strip (C260, 0.032")	Lock & Hinge Assembly	Projected shortfall of 180 kg in 2 weeks	3 hrs ago	Pending
▼	Demand Spike	Self-Drilling Screws (#12 Hex)	Hardware Distribution Center	Order volume 140% above forecast — monitor stock levels	5 hrs ago	Pending
●	Transfer Complete	Stainless Steel Coil (304, 1.2mm)	Wire & Rod Stockroom	6 tons received from Hardware Distribution Center	7 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
hardware
production lines.

Your hardware lines
run on
SKU volume overload.

Inventory & Production

Supply Chain & Operations

One system from
raw wire rod to
finished hardware.

See what your
hardware 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 hardware lines
deserve SKU-level visibility.

The controltower for yourhardwareproduction lines.

Your hardware linesrun onSKU volume overload.

Inventory & Production

Supply Chain & Operations

One system fromraw wire rod tofinished hardware.

See what yourhardware manufacturing operationslook like inside FalOrb.

Operations Dashboard

Overview

Production Orders

Production Orders

13-Type Alert System

Alerts

From stockoutto signal inunder a second.

Your hardware linesdeserve SKU-level visibility.

The control
tower for your
hardware
production lines.

Your hardware lines
run on
SKU volume overload.

One system from
raw wire rod to
finished hardware.

See what your
hardware manufacturing operations
look like inside FalOrb.

From stockout
to signal in
under a second.

Your hardware lines
deserve SKU-level visibility.