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Inventory & Production Management for Packaging & Plastics

The control
tower for your
packaging
operation.

High-volume runs, tight material margins, and constant changeovers. FalOrb gives packaging and plastics manufacturers real-time visibility into resin stock, mould schedules, and production readiness.

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Real-Time StockMaterial BOMATP EngineMRP PlanningResin TrackingSupplier ManagementTransfer EngineAudit LedgerReal-Time StockMaterial BOMATP EngineMRP PlanningResin TrackingSupplier ManagementTransfer EngineAudit Ledger
Packaging and Plastics operations
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.
Packaging and Plastics production

Inventory & Production

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

Supply chain operations

Supply Chain & Operations

MRP Horizons / Supplier Management / Alert System

Packaging and Plastics platform
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.

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 moulding floor
deserves precision.

FalOrb is built for packaging and plastics manufacturers where changeover efficiency determines margin and material waste is measured in tonnes. If that's your operation, let us show you what connected production looks like.

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