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Inventory & Production Management for Storage Media

The control
tower for your
media
production facility.

Precision substrates, magnetic coatings, and cleanroom-grade production environments. FalOrb gives storage media manufacturers real-time visibility into raw materials, coating formulations, production batches, and quality yields.

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Real-Time StockProcess BOMBatch TrackingMRP PlanningYield TrackingCleanroom InventorySupplier ManagementAudit LedgerReal-Time StockProcess BOMBatch TrackingMRP PlanningYield TrackingCleanroom InventorySupplier ManagementAudit Ledger
Magnetic and Optical Media Manufacturing operations
01 / The Problem - Cleanroom Floor
■ The Problem

Your media production
runs on
yield uncertainty.

Substrates measured in microns. Coating thickness tolerances in nanometres. Cleanroom particulate counts that determine whether an entire batch passes or fails. When yields drop, identifying whether the cause is substrate quality, coating process, or environment takes manual investigation across separate logs.

FalOrb was built for the precision demands of media manufacturing - where a single particulate contamination event can scrap an entire production batch.

Pain 01
Substrate Quality Variability
Substrate surface quality varies by supplier and batch. Incoming inspection results tracked separately from inventory records. No automated link between substrate quality grades and production line allocation.
Pain 02
Cleanroom Material Controls
All materials entering cleanroom environments must meet particulate standards. Packaging removed at airlock staging. Inventory counts inside and outside the cleanroom diverge. No unified view of clean-zone material availability.
Pain 03
Coating Process Yield Losses
Thin-film coating yields depend on equipment calibration, target material condition, and chamber environment. Yield data captured in process logs disconnected from inventory adjustments. Scrap quantities updated manually, often late.
Pain 04
Market Demand Decline Planning
Optical and magnetic media volumes declining in segments while growing in archival and specialty markets. Production mix shifting from high-volume commodity to low-volume specialty. No planning tool that supports dual demand patterns simultaneously.
Magnetic and Optical Media Manufacturing production

Inventory & Production

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

Supply chain operations

Supply Chain & Operations

MRP Horizons / Supplier Management / Alert System

Magnetic and Optical Media Manufacturing platform
02 / The Platform - Built for Magnetic and Optical Media Manufacturing
■ The Platform

One system from
raw substrate to
certified media.

FalOrb covers the full storage media lifecycle. Substrate inventory, coating formulation BOMs, cleanroom material management, batch tracking, and yield monitoring - all connected in one platform.

Every substrate is tracked. Every coating batch is recorded. Every yield variance is captured. From raw material receipt through cleanroom staging, coating, testing, and packaging to shipped media.

■ Platform in Action

See what your
magnetic and optical media manufacturing operations
look like inside FalOrb.

Real screens. Real layout. Simulated data from a magnetic and optical media 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

Overview

Updated just now
Refresh
5
Total Locations
3
Critical Items
5
Pending Transfers
11
Active Alerts
Manufacturing
12
Active Production Orders
2
Material Shortages
1
Products ATP Zero
3
MRP Shortfalls
Network
Disc Replication Plant
Production
Healthy
8 low 312 healthy 4 surplus
Substrate Coating Facility
Production
Low
3 critical 14 low 189 healthy
Media Packaging Center
Warehouse
Healthy
5 low 267 healthy
Regional Distribution Hub
Distribution
Critical
6 critical 11 low 143 healthy
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 12
Draft 2
Confirmed 3
In Progress 6
Completed 3
Order #ProductLocationQty OrderedQty ProducedMaterialStatus
PO-2026-4301Blu-ray BD-R 25GB 50-PackDisc Replication Plant18,00014,200SufficientIn Progress
PO-2026-4302LTO-9 Tape Cartridge 18TBSubstrate Coating Facility6,5000CriticalConfirmed
PO-2026-4303DVD-R 4.7GB Bulk SpindleDisc Replication Plant40,00040,000SufficientCompleted
PO-2026-4304M-DISC Archival Blu-ray 100GBSubstrate Coating Facility3,2001,850PartialIn Progress
PO-2026-4305UHD BD-XL 128GB Triple LayerDisc Replication Plant8,0000SufficientDraft
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 11
Active 8
Acknowledged 3
Resolved 1
TypeItemLocationMessageTriggeredStatus
▲Stock OutPolycarbonate Substrate BlanksSubstrate Coating FacilityStock depleted. Replication line halted pending resupply.12 min agoActive
▲Quality HoldSilver Alloy Reflective LayerDisc Replication PlantReflectivity test failure on incoming batch. Lot quarantined.1 hr agoActive
▼Low StockMagnetic Tape Pancakes (LTO)Substrate Coating FacilityStock at 18% of reorder point. 3-week supplier lead time.3 hrs agoPending
▼Expiry WarningUV-Curable Lacquer CoatingDisc Replication Plant2 drums expiring within 14 days. Prioritize consumption.5 hrs agoAcknowledged
●Transfer CompleteJewel Cases & Spindle HubsMedia Packaging CenterInbound transfer of 25,000 units received and verified.8 hrs 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 cleanroom production
deserves yield visibility.

FalOrb is built for storage media manufacturers where cleanroom contamination drives scrap, substrate quality determines yield, and production planning must balance declining commodity volumes with growing specialty demand. If that's your facility, let us show you what connected media manufacturing looks like.

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