Large-scale manufacturing and distribution companies face the challenge of efficiently managing thousands of material SKUs across multiple locations. In this project, Resivo’s main goal was to eliminate estimation-based decisions and create a cohesive analytical environment that directly links inventory levels with current demand, production schedules, and product technology.
The client managed an extensive warehouse network where inventory data operated in isolation from the actual needs of production halls and the sales department. This structure generated a series of operational and financial difficulties.
The lack of central visibility into the rotation rate of individual items led to maintaining high levels of slow-moving and obsolete inventory, which directly tied up the company’s working capital. On the other hand, out-of-stock events occurred regularly – production was halted due to the absence of critical components, even though overall warehouse stock levels were high.
An additional difficulty was the lack of precise information about the value of Work in Progress (WIP). Semi-finished products and raw materials circulating between production cells were difficult for financial controlling to estimate, which prevented accurate real-time cost accounting.
In response to these challenges, the Resivo team designed and implemented an advanced analytical platform based on the Microsoft technology ecosystem. Instead of limiting ourselves to historical reporting, we created an analytical engine that supports current purchasing and logistics decisions.
The tool consolidates data from distributed databases and automatically decomposes planned production orders according to Bill of Materials (BOM) structures. The algorithm calculates the demand for raw materials and semi-finished products over time, comparing it with available stock and materials already in intermediate stages within the WIP area.
The system calculates the optimal stock runway for each SKU and generates proactive notifications for the procurement department. This allows raw materials to be ordered precisely when they are required by the schedule, eliminating the need for excessive buffers.
The analytical mechanism also supports inter-warehouse management. By analyzing local demand and stock levels in individual facilities, the system suggests optimal transfers of goods between warehouses. As a result, surplus raw materials in one location are moved to where there is current production demand, preventing unnecessary purchases from suppliers.
Thanks to the implementation of Resivo’s solutions, the company gained full transparency of logistics and production processes. Management obtained a unified, reliable real-time picture of the financial and operational situation.
The combination of BOM analytics with production plans minimized the risk of production line stoppages due to lack of raw materials.
Identification of slow-moving items and automation of inter-warehouse transfers helped release funds frozen in excessive inventory.
The controlling department gained current and accurate valuation of Work in Progress, which translated into better management of finished product profitability.
The procurement department moved away from reactive ordering of goods to automatic suggestions based on the real production schedule.
Does your company keep up with current accounting without a hitch, or is month-end closing still a frantic race against time? Can you determine in two minutes the exact status and location of the last invoice from a key supplier?
If you feel that your processes or financial reporting are stuck in Excel bottlenecks, and your systems aren’t communicating – let’s talk. We’ll see what pieces we can quickly and painlessly fit into your existing architecture so you can finally gain peace of mind and data you can truly rely on for decisions.
+48 606 281 103
marcin@resivo.pl
