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Inventory & Production Management for Synthetic Materials

The control
tower for your
polymer
production plant.

Continuous process lines, petrochemical feedstocks, and batch-to-batch consistency requirements. FalOrb gives synthetic material manufacturers real-time visibility into feedstock inventory, process BOMs, production batches, and quality parameters.

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Real-Time StockProcess BOMBatch TrackingMRP PlanningFeedstock ManagementQuality ParametersTransfer EngineAudit LedgerReal-Time StockProcess BOMBatch TrackingMRP PlanningFeedstock ManagementQuality ParametersTransfer EngineAudit Ledger
Artificial Rubber and Synthetic Fiber Manufacturing operations
01 / The Problem - Process Plant
■ The Problem

Your polymer plant
runs on
batch-by-batch guesswork.

Petrochemical feedstock prices swing with crude markets. Continuous production lines can't pause while procurement confirms stock. Polymer grades vary by catalyst ratio, temperature profile, and additive blend. When a customer needs a specific grade, confirming availability means checking lab records and warehouse counts separately.

FalOrb was built for the process intensity of synthetic material production - where feedstock availability determines whether the line runs or idles.

Pain 01
Feedstock Price Volatility
Petrochemical inputs tied to crude oil and gas markets. Price windows for bulk procurement are narrow. No system link between market price signals and purchase order timing. Buying decisions reactive rather than strategic.
Pain 02
Grade and Spec Proliferation
Multiple polymer grades with different additive packages, viscosities, and tensile specifications. Each grade requires a distinct process BOM. Grade changeovers consume production time and generate transition waste.
Pain 03
Continuous Line Scheduling
Process lines run continuously with planned changeovers. Scheduling optimises for minimum grade transitions. No integrated view of customer orders, feedstock availability, and line capacity in a single planning tool.
Pain 04
Quality and Consistency Tracking
Batch properties depend on process parameters and feedstock quality. Off-spec batches discovered after production, not during. No real-time link between process data and inventory quality records.
Artificial Rubber and Synthetic Fiber Manufacturing production

Inventory & Production

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

Supply chain operations

Supply Chain & Operations

MRP Horizons / Supplier Management / Alert System

Artificial Rubber and Synthetic Fiber Manufacturing platform
02 / The Platform - Built for Artificial Rubber and Synthetic Fiber Manufacturing
■ The Platform

One system from
raw feedstock to
finished polymer.

FalOrb covers the full synthetic material lifecycle. Feedstock inventory, process BOM management, continuous production scheduling, quality tracking, and dispatch - all connected with full batch traceability.

Every feedstock delivery is recorded. Every process parameter is linked. Every grade changeover is tracked. From petrochemical input through polymerisation and finishing to packaged product dispatch.

■ Platform in Action

See what your
artificial rubber and synthetic fiber manufacturing operations
look like inside FalOrb.

Real screens. Real layout. Simulated data from a artificial rubber and synthetic fiber 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
2
Critical Items
5
Pending Transfers
10
Active Alerts
Manufacturing
12
Active Production Orders
2
Material Shortages
1
Products ATP Zero
3
MRP Shortfalls
Network
Polymerization Plant
Production
Healthy
4 critical 14 low 298 healthy
Monomer Storage Facility
Warehouse
Low
9 critical 22 low 156 healthy
Fiber Spinning Mill
Production
Healthy
2 critical 16 low 241 healthy
Finished Goods Warehouse
Distribution
Healthy
8 low 312 healthy 18 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

Production Orders

+ New Order
All 12
Draft 2
Confirmed 3
In Progress 6
Completed 3
Order #ProductLocationQty OrderedQty ProducedMaterialStatus
PO-2026-4311Nylon 6,6 Staple Fiber (3.0 dtex)Fiber Spinning Mill32,00021,500SufficientIn Progress
PO-2026-4312SBR 1502 Synthetic Rubber BalePolymerization Plant14,00014,000SufficientCompleted
PO-2026-4313Polyester POY 150D/48FFiber Spinning Mill28,0009,200PartialIn Progress
PO-2026-4314EPDM Rubber Compound (60 Shore A)Polymerization Plant8,5000CriticalConfirmed
PO-2026-4315Acrylic Tow 3.3 dtex BrightFiber Spinning Mill18,0000SufficientDraft
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 10
Active 8
Acknowledged 3
Resolved 1
TypeItemLocationMessageTriggeredStatus
▲Stock OutAdipic Acid (Polymer Grade)Monomer Storage FacilityZero stock — Nylon 6,6 line halted8 min agoActive
▲Quality Hold1,3-Butadiene MonomerMonomer Storage FacilityBatch BT-4402 failed purity spec — quarantined45 min agoActive
▼Low StockEthylene Propylene Diene MonomerPolymerization PlantStock at 18% of safety level — supplier lead time 21 days2 hr agoPending Review
▼Temperature ExcursionStyrene Monomer (Inhibited)Monomer Storage FacilityTank T-08 temperature at 28°C — max threshold 25°C4 hr agoEscalated
●SurplusTitanium Dioxide DelustrantFinished Goods WarehouseStock 165% above max — reduce next PO quantity6 hr agoNoted
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 process line
deserves connected planning.

FalOrb is built for synthetic material manufacturers where feedstock timing drives margins, grade consistency determines customer retention, and continuous lines demand uninterrupted material flow. If that's your operation, let us show you what connected production looks like.

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