Inventory Operations
MOM-specific inventory management — material staging, WIP tracking, kanban replenishment, and production material consumption.
Overview
The Inventory Operations module sits between the Warehouse and Manufacturing Execution modules. While the Warehouse handles receiving, slotting, and general stock management, Inventory Operations focuses exclusively on the production floor: getting the right materials to the right workstation at the right time, tracking work-in-process quantities as production progresses, replenishing materials using a lean kanban pull system, and recording the actual materials consumed against each work order.
All four screens share the same JSON data store (inventory-operations.json) and integrate directly with Manufacturing Execution (work orders, BOMs, routing) and the Warehouse module (stock reservation and consumption).
Material Staging
Pick and stage BOM-required materials from the warehouse to workstation racks before production starts. Tracks staged vs required quantities per item with color-coded status.
WIP Tracking
Real-time work-in-process quantities across all active work orders. Drill down to individual operations to see per-step started, completed, and scrap counts.
Kanban Replenishment
Pull-system kanban board with four columns: To Order, Ordered, In Transit, Available. Cards are drag-and-drop — move a card between columns to update its status instantly. Stock level bars show when cards fall below reorder point.
Material Consumption
Record actual quantities consumed per work order operation, attributed to the logged-in operator. Scrap quantities automatically create an NCR in the Quality Operations module — no manual step required.
Module Placement
Inventory Operations is its own App Mode — switch to it via the mode badge in the top header (teal badge labelled Inv Ops). It does not appear inside Manufacturing Mode or Warehouse Mode; it has its own dedicated sidebar group.
Production Material Flow
The four screens map to a sequential production material lifecycle. A work order moves through all four stages before materials are fully consumed:
Material Staging
Pull BOM materials from warehouse shelves and place them on the workstation rack. Confirm staging when all items are ready.
WIP Tracking
As the work order runs, WIP quantities accumulate per operation. Monitor progress and spot bottlenecks in real time.
Kanban Replenishment
When kanban cards drop below reorder point, trigger purchase orders. Receive stock to return cards to Available.
Material Consumption
Record actual material consumed per operation. Reduce warehouse stock; any scrap automatically creates an NCR in Quality Operations.
Screen Reference
Material Staging
Select a released work order, stage materials by item, scan or enter quantities, confirm staging complete.
WIP Tracking
Table of active work orders with started / completed / scrap / WIP columns and per-operation drill-down.
Kanban Replenishment
Four-column pull board for managing material replenishment cards — order, transit, and receive stock.
Material Consumption
Record consumed and scrap quantities per material per operation; view full consumption history.
Integration Map
| External Module | Integration Point | Direction |
|---|---|---|
| Manufacturing Execution | Work order status, BOM component list, routing operations | Reads from MFG |
| Warehouse | Stock reservation on staging, stock reduction on consumption, stock receipt on kanban receive | Reads & writes |
| Quality Operations | Scrap quantities recorded in Consumption automatically create an NCR in the Non-Conformance screen — pre-filled with work order, operation name, scrap reason, and operator identity | Writes to QO |
| Purchase | Kanban "Create Order" action creates a purchase request in the Purchase module | Writes to Purchase |
Data Storage
All Inventory Operations data is persisted server-side via the /api/data/inventory-operations endpoint to data/inventory-operations.json. The store contains four top-level objects:
| Key | Contains |
|---|---|
stagings | One staging record per work order — items array, staged quantities, locations, status |
wipEntries | WIP snapshot per work order — per-operation started / completed / scrap / wip counts |
kanbanCards | All kanban replenishment cards — product, stock levels, status, linked purchase order ID |
consumptions | All material consumption records — per-item consumed / scrap quantities, timestamps, operator |