Packaging & Plastics Inventory & Production Software

01 / The Problem - Moulding Floor

■ The Problem

Your moulding floor
runs on
reactive scheduling.

Resin inventory estimated by bin level. Mould changeovers scheduled without confirming material availability. Colour and grade variants tracked informally. When a customer order spikes, finding available capacity and stock takes too long.

FalOrb was built for the throughput demands of packaging - where downtime between changeovers directly impacts margin and material waste is the enemy.

Pain 01

Resin & Raw Material Guesswork

Resin inventory estimated by silo level or bin weight. Grade and colour variants not tracked at granular level. Production starts without confirming the right material is available in the right quantity.

Pain 02

Changeover Scheduling Chaos

Mould and line changeovers scheduled manually without linking to material availability. Setup time and scrap from changeovers not factored into production planning. Efficiency leaks go unmeasured.

Pain 03

Customer Order Whiplash

Large customer orders arrive with short lead times. No ATP visibility to confirm delivery dates. Commitments made on assumptions, not data. Missed deliveries erode customer relationships.

Pain 04

Scrap and Waste Invisible

Material waste from startups, changeovers, and rejects not tracked against production orders. Actual vs. theoretical material usage unknown. Margin erosion goes undetected until month-end.

02 / The Platform - Built for Packaging and Plastics

■ The Platform

One system from
raw resin to
shipped packaging.

FalOrb covers the full packaging lifecycle. Resin and raw material tracking, mould-based BOM management, production orders with variance tracking, and procurement planning - all connected.

Every material movement is recorded. Every production run tracks actual vs. planned usage. Every discrepancy surfaces immediately. From resin receipt through moulding to finished goods dispatch.

■ Platform in Action

See what your
packaging and plastics operations
look like inside FalOrb.

Real screens. Real layout. Simulated data from a packaging and plastics 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

Injection Molding Bay

Production

Healthy

1 critical 10 low 126 healthy

Extrusion Line

Production

Low

4 critical 15 low 98 healthy

Resin & Additive Store

Warehouse

Healthy

6 low 74 healthy 3 surplus

Finished Goods Warehouse

Distribution

Healthy

5 low 188 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

All 12

Draft 2

Confirmed 3

In Progress 6

Completed 3

Order #	Product	Location	Qty Ordered	Qty Produced	Material	Status
PO-2026-8101	PET Bottle Preform 28mm	Injection Molding Bay	100,000	72,000	Sufficient	In Progress
PO-2026-8102	LDPE Shrink Film 25μm	Extrusion Line	30,000	30,000	Sufficient	Completed
PO-2026-8103	Polypropylene Food Container 750ml	Injection Molding Bay	60,000	18,400	Partial	In Progress
PO-2026-8104	Corrugated Box RSC A4	Finished Goods Warehouse	25,000	0	Critical	Confirmed
PO-2026-8105	HDPE Jerry Can 5L	Injection Molding Bay	8,000	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 9

Active 8

Acknowledged 3

Resolved 1

	Type	Item	Location	Message	Triggered	Status
▲	Stock Critical	PET Resin Bottle Grade	Resin & Additive Store	1.2 tonnes remaining vs 8 tonnes required for current orders.	2 min ago	Active
▼	Stock Low	UV Stabilizer Tinuvin 328	Resin & Additive Store	Below reorder point. 15 days lead time from specialty supplier.	18 min ago	Acknowledged
▼	PO Overdue	Kraft Liner 200gsm	Finished Goods Warehouse	Paper mill shipment delayed 2 days due to transport disruption.	1 hr ago	Acknowledged
▼	Consumption Anomaly	Masterbatch Blue 5015	Extrusion Line	Colorant dosage 18% above specification. Check feeder calibration.	2 hrs ago	Acknowledged
●	Stock Low	PP Copolymer Random	Resin & Additive Store	6 days supply remaining. Next tanker delivery confirmed for Monday.	5 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
packaging
operation.

Your moulding floor
runs on
reactive scheduling.

Inventory & Production

Supply Chain & Operations

One system from
raw resin to
shipped packaging.

See what your
packaging and plastics 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 moulding floor
deserves precision.

The controltower for yourpackagingoperation.

Your moulding floorruns onreactive scheduling.

Inventory & Production

Supply Chain & Operations

One system fromraw resin toshipped packaging.

See what yourpackaging and plastics operationslook like inside FalOrb.

Operations Dashboard

Overview

Production Orders

Production Orders

13-Type Alert System

Alerts

From stockoutto signal inunder a second.

Your moulding floordeserves precision.

The control
tower for your
packaging
operation.

Your moulding floor
runs on
reactive scheduling.

One system from
raw resin to
shipped packaging.

See what your
packaging and plastics operations
look like inside FalOrb.

From stockout
to signal in
under a second.

Your moulding floor
deserves precision.