Primary Metal Inventory Management & Production Planning Software

01 / The Problem - Melt Shop

■ The Problem

Your melt shop
runs on
charge-by-charge estimation.

Scrap yards with thousands of tonnes in mixed grades. Ore deliveries with varying metal content. Furnace charges calculated to hit target chemistry within tight ranges. When the spectrometer reading comes back off-spec, the correction window is minutes before the heat must pour. Your charge calculation is only as good as the scrap quality data you fed into it.

FalOrb was built for the process intensity of primary metals - where a furnace heat that misses chemistry costs hours of correction or an entire heat downgrade.

Pain 01

Scrap Yard Inventory Accuracy

Scrap stored in bins by grade classification. Actual chemistry varies within grade bands. Inventory measured by weight with no real-time chemical composition tracking. Furnace charge recipes based on assumed scrap quality.

Pain 02

Furnace Chemistry Control

Target chemistry must be hit within narrow ranges per grade specification. Alloy additions calculated against assumed charge composition. Off-spec heats require costly corrections or downgrading. No predictive tool optimising charge mix against target chemistry.

Pain 03

Heat-to-Product Traceability

Every finished product must trace to its source heat with full chemical and mechanical property records. Mill test certificates generated per heat lot. Traceability records maintained across melt shop, casting, and rolling in separate systems.

Pain 04

Energy Cost Optimisation

Furnace operations consume massive energy. Electric arc furnace scheduling affected by electricity pricing periods. No planning tool that aligns furnace scheduling with energy cost windows and production demand.

02 / The Platform - Built for Primary Metal Manufacturing

■ The Platform

One system from
raw charge to
certified metal product.

FalOrb covers the full primary metal lifecycle. Scrap and ore inventory, furnace charge BOM management, heat tracking, rolling and finishing schedules, and mill certificate generation - all connected with heat-level traceability.

Every scrap charge is tracked. Every heat is recorded. Every product is certified. From raw material receipt through melting, casting, rolling, and finishing to certified and dispatched metal products.

■ Platform in Action

See what your
primary metal manufacturing operations
look like inside FalOrb.

Real screens. Real layout. Simulated data from a primary metal 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

Electric Arc Furnace Mill

Production

Critical

8 critical 22 low 142 healthy

Scrap & Alloy Yard

Warehouse

Low

3 critical 11 low 198 healthy

Rolling & Finishing Plant

Production

Healthy

6 low 234 healthy

Great Lakes Metal Distribution

Distribution

Healthy

356 healthy 4 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 16

Draft 2

Confirmed 3

In Progress 6

Completed 3

Order #	Product	Location	Qty Ordered	Qty Produced	Material	Status
PO-2026-4731	Hot-Rolled Coil (A36)	Electric Arc Furnace Mill	2,400	1,680	Partial	In Progress
PO-2026-4732	Aluminum Billet (6061-T6)	Rolling & Finishing Plant	800	0	Critical	Confirmed
PO-2026-4733	Cold-Rolled Sheet (304 SS)	Rolling & Finishing Plant	1,200	1,200	Sufficient	Completed
PO-2026-4734	Copper Cathode (Grade A)	Electric Arc Furnace Mill	500	210	Critical	In Progress
PO-2026-4735	Galvanized Coil (G90)	Rolling & Finishing Plant	1,800	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 14

Active 8

Acknowledged 3

Resolved 1

	Type	Item	Location	Message	Triggered	Status
▲	Stock Out	Ferrosilicon (75%)	Electric Arc Furnace Mill	Ferrosilicon depleted; deoxidation step cannot proceed for current heat	8 min ago	Active
▲	Below Minimum	Scrap Steel (HMS #1)	Scrap & Alloy Yard	Scrap inventory at 4% of minimum; next melt schedule at risk	45 min ago	Active
▲	Equipment Alert	Graphite Electrode (UHP)	Electric Arc Furnace Mill	Electrode consumption 20% above forecast; only 3 spares remaining	2 hr ago	Active
▼	Supplier Delay	Aluminum Ingot (P1020A)	Rolling & Finishing Plant	Primary aluminum shipment delayed 7 days from smelter	4 hr ago	Monitoring
●	Reorder Triggered	Zinc Ingot (SHG)	Rolling & Finishing Plant	Auto-reorder placed for 18 tonnes zinc for galvanizing line	7 hr 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
metal production
facility.

Your melt shop
runs on
charge-by-charge estimation.

Inventory & Production

Supply Chain & Operations

One system from
raw charge to
certified metal product.

See what your
primary metal 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 melt shop
deserves heat-level clarity.

The controltower for yourmetal productionfacility.

Your melt shopruns oncharge-by-charge estimation.

Inventory & Production

Supply Chain & Operations

One system fromraw charge tocertified metal product.

See what yourprimary metal manufacturing operationslook like inside FalOrb.

Operations Dashboard

Overview

Production Orders

Production Orders

13-Type Alert System

Alerts

From stockoutto signal inunder a second.

Your melt shopdeserves heat-level clarity.

The control
tower for your
metal production
facility.

Your melt shop
runs on
charge-by-charge estimation.

One system from
raw charge to
certified metal product.

See what your
primary metal manufacturing operations
look like inside FalOrb.

From stockout
to signal in
under a second.

Your melt shop
deserves heat-level clarity.