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.
Smart Inventory Management for Textile Mills
Textile mills in Coimbatore, Tirupur, Surat, and Bengaluru juggle thousands of SKUs across yarn, fabric, dyes, chemicals, and accessories. Materials are constantly moving between godowns, dyeing units, finishing lines, and dispatch areas, so physical stock rarely matches ERP records. This chaos leads to stockouts, excess inventory, and costly write-offs.
Boolean & Beyond builds smart inventory systems that give mills accurate, real-time visibility into every material at every location. RFID tags on yarn cones and fabric rolls, barcode labels on accessories and chemical containers, and IoT-enabled scales at receiving and issue points create a continuous digital trail of all material movements.
The system tracks:
- Quantities and locations across all stores and production areas
- Material age and expiry, critical for dyes and chemicals
- Lot traceability, linking yarn lots to finished fabric
- Quality grades, so planners know what is usable for which orders
AI-powered demand forecasting analyses historical consumption and the live order book to predict material requirements 4–8 weeks ahead. Dynamic safety stocks are calculated based on lead times and consumption velocity, and automatic reorder alerts prevent stockouts without overstocking.
Implementation Approach
Phase 1: Material Master & Infrastructure (Weeks 1–3)
- Audit current inventory processes with stores and procurement teams in Coimbatore or Bengaluru
- Clean and standardise material master data and SKU coding across locations
- Design the optimal mix of RFID, barcoding, and IoT sensors based on material criticality and warehouse layout
- Assign RFID to high-value yarn and fabric rolls; use barcodes for lower-value consumables and accessories
Phase 2: System Development & ERP Integration (Weeks 4–8)
- Build the inventory management application with real-time dashboards and mobile apps for floor staff
- Integrate with SAP, Oracle, Tally, or textile-specific ERPs
- Sync purchase orders, goods receipts, issue notes, and returns automatically to eliminate manual reconciliation
Phase 3: Rollout & Process Adoption (Weeks 9–12)
- Start deployment with highest-value materials (typically yarn and speciality fabrics)
- Train stores and production personnel on scanning and receiving/issue workflows
- Expand coverage material by material until all categories are included
- Allow the AI forecasting model to learn from actual consumption over 3–4 months, improving prediction accuracy
Results & ROI
Textile mills implementing Boolean & Beyond’s smart inventory systems typically achieve:
- Inventory accuracy: 98%+ vs 70–80% with manual systems
- Stockout reduction: 60–80% fewer production stops due to material unavailability
- Carrying cost reduction: 15–25% lower inventory holding costs
- Write-off reduction: 40–60% fewer material write-offs via FIFO and expiry tracking
- Procurement efficiency: 50% fewer emergency purchases thanks to advance demand visibility
- ROI: Payback within 6–10 months through reduced stockouts, lower carrying costs, and fewer write-offs
Integration with Existing Mill Infrastructure
Boolean & Beyond’s system is designed to work with existing ERPs and warehouse layouts:
- Retrofit RFID readers and barcode scanners into current godowns with minimal disruption
- Provide consolidated, real-time inventory visibility across multiple locations (yarn store, fabric warehouse, dye store, accessories godown)
- Enable supplier integration for automatic PO generation and goods receipt matching
- Link quality inspection data directly to inventory records so planners see both quantity and quality
- Track job-work and customer-supplied materials separately, maintaining clear ownership and consumption records
For textile manufacturers in Coimbatore, Tirupur, Surat, and Bengaluru, Boolean & Beyond turns inventory management from guesswork into a precise, data-driven process using RFID, IoT, and AI-powered forecasting.