The client
The client is a large manufacturing enterprise with multiple production units across India.
Production depends on spare parts, consumables, production materials and everyday supplies held in warehouses, stores and stock points at each unit. A missing part can stop a line while it is ordered.
The challenge
Replenishment depended on manual stock reviews, spreadsheets and follow-ups between store and purchase teams. Critical items were sometimes noticed only after stock had fallen too low.
- Recurring shortages of spare parts, consumables and production materials.
- Stock records kept in spreadsheets at each location.
- No reorder controls, so planning was reactive.
- Delays while store and purchase teams followed up with each other.
What they set up in Asset Infinity
The manufacturer centralized its inventory in Asset Infinity and set minimum stock levels and reorder alerts for critical items at every location.
One inventory across units
Spare parts, consumables, materials and supplies are tracked in one system, organized by warehouse, store and stock point. (Stores)
Minimum levels from consumption
Minimum stock levels and reorder points for critical items were set from what each location actually consumes. (Stores)
Reorder alerts
When an item reaches its minimum level, it appears on the reorder list and the teams responsible are notified. (Stores)
Purchasing from current stock
Purchase requests are raised from the reorder advice, with current stock in view, so purchasing does not wait for a follow-up. (Suppliers)
How it works day to day
Here is how parts and materials are kept in stock now.
- Storekeeper: records every movement. Parts and materials received and issued at each store are recorded in the system, so stock levels are current.
- Technician: draws parts for a job. Spare parts used in a repair are issued to the work order, which reduces stock at that store.
- System: flags the reorder level. When a critical item reaches its minimum level, it is added to the reorder list and the responsible teams are notified.
- Store manager: checks other locations. Before ordering, the manager can see stock of the same item at other warehouses and stock points.
- Purchasing: raises the request. A purchase request is raised from the reorder advice and moves through approval to a purchase order.
- Storekeeper: receives the delivery. The delivery is received against the purchase order and the stock level updates.
Before and after
| Before | With Asset Infinity | |
|---|---|---|
| Stock records | Spreadsheets at each location | One inventory across warehouses and stores |
| Finding low stock | Manual stock reviews | Alerts at defined minimum levels |
| Critical items | Noticed only after stock fell too low | Flagged before they run out |
| Replenishment | Delayed by follow-ups | Teams notified when reorder levels are reached |
| Planning | Reactive | Based on current stock across locations |
How it rolled out
- Inventory centralized. Stock records for parts, consumables, materials and supplies were brought into one system from every location.
- Locations and levels set. Warehouses, stores and stock points were mapped, and minimum levels set for critical items.
- Teams trained. Inventory and purchasing teams were trained on reorder alerts and the replenishment workflow.
The results
- Better availability of critical inventory through predefined minimum levels
- Low stock is identified before items become unavailable
- Faster replenishment, with teams notified when reorder levels are reached
- Less dependence on manual stock reviews and spreadsheets
- Better coordination between stores, operations and purchasing
Why it worked
Levels set from real use
Minimum levels followed each location’s consumption, so alerts came at the right time.
All locations in one place
Mapping every warehouse and stock point meant stock was counted where it actually sits.
Purchasing in the loop
Store and purchase teams see the same alerts, so replenishment starts without a chase.
Looking ahead
The manufacturer moved from finding shortages after the fact to managing replenishment ahead of time. Minimum levels and alerts tell teams when stock needs attention, at every location.
Current stock visibility now supports purchasing and planning decisions across the company, and store, operations and purchasing teams work from the same numbers.