Smart Inventory Management for Yarn, Fabric, and Accessories

Inaccurate inventory causes stockouts and excess carrying costs. Smart inventory systems with RFID and real-time tracking solve the visibility problem.

The Problem

Physical counts rarely match system records, especially for yarn and small accessories
Stockouts halt production while excess inventory ties up working capital
FIFO compliance is difficult to enforce in busy warehouses
No visibility into inventory turns or slow-moving stock
Multiple godowns make centralized tracking nearly impossible

Hidden Costs

Production delays waiting for materials that were supposedly in stock
Emergency purchases at premium prices to cover stockouts
Carrying costs on excess inventory (10-25% of value annually)
Write-offs for expired, damaged, or obsolete materials
Labor costs for frequent manual cycle counts

Modern Approach

RFID gates automatically track material movements in and out
Real-time inventory dashboards across all warehouse locations
AI-powered reorder suggestions based on consumption patterns
Automated alerts for slow-moving stock and expiry dates
Integration with procurement and production planning systems

Implementation Details

Technical approach, timelines, and expected outcomes

What We Build

Barcode scanning for yarn, fabric, and dye stock. A real-time inventory dashboard showing quantities, locations, and age of stock. Automated reorder alerts when materials hit minimum levels.

The system tracks consumption against production orders. You see exactly which materials are allocated, available, or running low.

How It Works

Stock movements are scanned at receiving, issue to production, and returns. The system updates quantities instantly. Production planning sees real availability. Purchasing gets alerts before stockouts happen.

Who This Is For

Mills managing 500+ SKUs of yarn and fabric. If physical counts don't match records, or if production stops because materials weren't available, this system fixes that.

Frequently Asked Questions

Why do physical inventory counts not match system records?

Common causes include unrecorded movements, data entry errors, theft, damage, and items stored in wrong locations. Without real-time tracking, discrepancies compound over time until physical counts are the only way to correct records.

How does RFID inventory tracking work in textile mills?

RFID tags attached to yarn cones, fabric rolls, or bins contain unique identifiers. RFID gates or handheld readers detect items as they move in and out of storage areas, updating inventory automatically without manual scanning.

What is the cost of poor inventory management?

Poor inventory costs 10-25% of inventory value annually through stockouts, excess carrying costs, emergency purchases at premium prices, obsolete stock write-offs, and labor for manual counting.

How do automated reorder alerts prevent stockouts?

The system monitors consumption patterns and current stock levels. When inventory drops below minimum thresholds, it automatically alerts purchasing with reorder quantities based on lead times and usage forecasts.

Can inventory software handle multiple warehouse locations?

Yes. Modern systems track inventory across multiple godowns with location-level visibility. You see total stock, location-specific quantities, and can transfer materials between locations with full traceability.

Get accurate inventory counts without disrupting operations. Let's discuss an RFID pilot for your highest-value materials.

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Registered Office

Boolean and Beyond

825/90, 13th Cross, 3rd Main

Mahalaxmi Layout, Bengaluru - 560086

Operational Office

590, Diwan Bahadur Rd

Near Savitha Hall, R.S. Puram

Coimbatore, Tamil Nadu 641002

Textile Inventory Management Software | RFID Tracking for Mills | Boolean & Beyond