Inventory accuracy
Stock that matches the rack
Material issued and consumed by lot against the work order. Shortages seen before the line starts.
The situation
The system says 1,480 metres. The rack has 900.
Issues are written on a slip and posted later. Consumption is worked out at month end from what is left. Shortages are found at the machine, and subcontracted material comes back short without anyone noticing until the reconciliation.
- Purchase decisions are made from a stock figure nobody trusts, so everyone over-orders.
- A line stops for an item that the system says is in stock.
- Over-consumption on an order is found weeks after the margin is gone.
- Job-work material goes out on a slip and the short return is never chased.
On FleekERP
Issue by lot, consume by operation, see the shortage first
Stores issues a lot to the work order. When the operator completes the operation, consumption is calculated from the BOM against that lot. Stock moves with the floor. Material readiness shows the next three shifts' needs against what is on hand, allocated and on order.
- 1Receive and issue by lotEvery receipt carries a lot. Every issue is against a work order. The rack and the record move together.
- 2Consume on completionOperation complete triggers BOM consumption against the issued lots. Over-consumption shows on the order the same day.
- 3Shortage names the orderMaterial readiness lists what is short and which order it will stop. Alternates appear next to blocked items.
Capabilities that do the work
Which parts of the platform run this
“When a style starts eating more fabric than planned, I know the same day, not at month end.”
Questions about inventory accuracy
Do we have to count stock to start?
An opening stock by lot is loaded during implementation. From then on, receipts, issues and consumption keep it current. A cycle count screen records differences with a reason.
How does subcontracted material stay accurate?
Material leaves on a challan with a quantity. The return is recorded against that challan. The difference is the short return, on the order and on the vendor.
Does stock value sync to Tally?
Yes. Purchases, sales and stock values sync to Tally or Zoho. The lot-level movement stays in FleekERP.
Next step
See inventory accuracy on your floor
Bring the situation as it is today. We map the demo to your lines, your products and your reason codes.