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Inventory & Production Management for Plastics & Rubber

The control
tower for your
plastics
production operation.

Polymer resins, masterbatch colorants, and mould tooling across injection, extrusion, and blow moulding lines. FalOrb gives plastics manufacturers real-time visibility into resin inventories, product BOMs, machine schedules, and mould tooling status.

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Real-Time StockProduct BOMBatch TrackingMRP PlanningMould ManagementResin TrackingSupplier ManagementAudit LedgerReal-Time StockProduct BOMBatch TrackingMRP PlanningMould ManagementResin TrackingSupplier ManagementAudit Ledger
Plastics and Rubber Product Manufacturing operations
01 / The Problem - Moulding Floor
■ The Problem

Your moulding floor
runs on
resin bin estimates.

Resin silos and gaylord bins with no real-time level monitoring. Masterbatch colour lots that vary between deliveries. Moulds that degrade over shot counts with no preventive maintenance trigger. When a customer order arrives, confirming resin availability, mould readiness, and machine capacity requires checking three separate systems.

FalOrb was built for the high-volume, multi-machine reality of plastics manufacturing - where resin stockouts stop machines and mould failures create scrap.

Pain 01
Resin Inventory Visibility
Bulk resin stored in silos and bins without real-time level tracking. Consumption rates estimated from production records. Reorder points based on assumptions, not actual consumption. Stockouts discovered when the hopper runs dry.
Pain 02
Mould and Tool Lifecycle
Moulds degrade over shot counts affecting part quality. Preventive maintenance schedules based on estimates. No automated tracking of actual shot counts per mould to trigger maintenance or replacement before quality failures.
Pain 03
Colour and Additive Matching
Masterbatch colour lots vary between deliveries. Colour matching requires test shots and adjustments. No system linking colour approval records to masterbatch lot numbers for batch-to-batch consistency.
Pain 04
Scrap and Regrind Management
Runners, sprues, and defective parts ground for regrind. Regrind mixed back into virgin resin at specific ratios. No tracking of regrind generation rates, current regrind inventory, or blend ratios per production run.
Plastics and Rubber Product Manufacturing production

Inventory & Production

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

Supply chain operations

Supply Chain & Operations

MRP Horizons / Supplier Management / Alert System

Plastics and Rubber Product Manufacturing platform
02 / The Platform - Built for Plastics and Rubber Product Manufacturing
■ The Platform

One system from
raw resin to
moulded product.

FalOrb covers the full plastics and rubber manufacturing lifecycle. Resin inventory tracking, product BOM management, mould lifecycle monitoring, machine scheduling, and regrind management - all connected in one platform.

Every resin lot is tracked. Every shot count is logged. Every regrind ratio is recorded. From raw resin receipt through drying, moulding, trimming, and assembly to packed and dispatched products.

■ Platform in Action

See what your
plastics and rubber product manufacturing operations
look like inside FalOrb.

Real screens. Real layout. Simulated data from a plastics and rubber product 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
6
Total Locations
3
Critical Items
6
Pending Transfers
11
Active Alerts
Manufacturing
15
Active Production Orders
2
Material Shortages
1
Products ATP Zero
4
MRP Shortfalls
Network
Injection Molding Plant
Production
Low
4 critical 16 low 192 healthy
Resin & Compound Warehouse
Warehouse
Healthy
287 healthy 5 surplus
Rubber Extrusion Facility
Production
Healthy
7 low 156 healthy
Midwest Polymer Distribution
Distribution
Critical
5 critical 9 low 224 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 15
Draft 2
Confirmed 3
In Progress 6
Completed 3
Order #ProductLocationQty OrderedQty ProducedMaterialStatus
PO-2026-4721HDPE Container Lids (32 oz)Injection Molding Plant250,000178,500SufficientIn Progress
PO-2026-4722EPDM Weatherstrip ProfileRubber Extrusion Facility45,0000CriticalConfirmed
PO-2026-4723PVC Rigid Pipe (4 in Sch 40)Injection Molding Plant18,00018,000SufficientCompleted
PO-2026-4724Silicone Gasket Ring (FDA)Rubber Extrusion Facility120,00054,600PartialIn Progress
PO-2026-4725PP Crate (Stackable)Injection Molding Plant30,0000SufficientDraft
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 OutEPDM Rubber Compound (60A)Rubber Extrusion FacilityEPDM compound depleted; weatherstrip production halted18 min agoActive
▲Below MinimumHDPE Resin (Blow Grade)Injection Molding PlantResin stock at 6% of minimum; container line shutting down1 hr agoActive
▼Temperature ExcursionPlatinum Cure SiliconeResin & Compound WarehouseStorage temp exceeded 30C for silicone lot SIL-0408; shelf life reduced3 hr agoPending Review
▼Supplier DelayCarbon Black (N330)Rubber Extrusion FacilityShipment delayed 5 days; impacts vulcanization batch schedule5 hr agoMonitoring
●Reorder TriggeredPP Homopolymer PelletsInjection Molding PlantAuto-reorder placed for 12,000 kg polypropylene pellets9 hr 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 moulding floor
deserves resin-level visibility.

FalOrb is built for plastics manufacturers where resin availability drives machine uptime, mould condition determines part quality, and regrind ratios affect material costs. If that's your operation, let us show you what connected plastics production looks like.

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