Inventory Management Software Development

Unified inventory visibility across warehouses, retail locations, 3PL partners, and in-transit stock. The data model uses a PostgreSQL multi-warehouse schema with a normalised location hierarchy (site, zone, aisle, bin) that supports precise putaway rules and pick path optimisation without collapsing into a flat "warehouse ID" that breaks under real operational complexity.

Location-specific stock levels, stock transfer workflows, and allocation rules determine which location fulfils which orders, nearest location first, lowest-pick-cost first, or reserve a location for specific customer classes. ABC/XYZ analysis classifies stock by movement frequency and demand variability, enabling fast-moving A items to be slotted in forward pick locations and slow-moving C items stored in bulk locations with cycle counts scheduled accordingly. Reorder point automation calculates the trigger quantity per SKU per location using the EOQ formula weighted against supplier lead time and target service level, then fires a replenishment suggestion or a direct PO when stock crosses the threshold. Safety stock is calculated as Z multiplied by demand standard deviation multiplied by the square root of lead time (Z * sigma * sqrt(L)), where Z is set by your target fill rate, so the safety stock buffer reflects actual demand variability rather than a fixed weeks-of-cover guess.

Cross-location reporting for buying decisions covers committed stock (reserved for open orders), available-to-promise, and stock in transit between locations. Automated stock transfer triggers fire when a location falls below its reorder point and a surplus location exists, reducing inter-site transfer lead times.

Full forward and backward traceability for lot-tracked and serial-tracked inventory. Lot receipt with supplier lot number capture, FIFO/FEFO stock rotation enforcement, lot expiry date management, and lot-specific quality hold workflow. Serial number tracking from receipt through sale with full chain of custody. Recall management, identify all locations and customer orders containing a specific lot in seconds.

Bill of materials management for kits and assembled products, with multi-level BOM support for assemblies that consume sub-assemblies. Component reservation and allocation when a kit order is received, the system commits component stock immediately so parallel orders do not over-allocate the same inventory. Assembly work order workflow generates a pick list, deducts components from bin-level locations using FIFO or FEFO rotation, and books the finished good to stock on receipt.

Barcode and QR scanning integration accelerates component pick verification: the operator scans each component bin and quantity before the work order is marked complete, catching pick errors before the kit ships. Zebra and Honeywell handheld scanner integration is handled via DataWedge intent broadcast or direct SDK depending on the device, with offline queue support for work orders in low-connectivity warehouse zones. Phantom BOM support handles virtual kits assembled at order time without a formal work order, enabling your e-commerce platform to sell kits that are picked component-by-component rather than requiring pre-assembled stock. Kit cost roll-up aggregates component unit costs at the landed cost level (including freight and duty allocation), giving accurate gross margin reporting per kit SKU. ERP integration passes finished-good inventory transactions to SAP MM, Oracle, or NetSuite in real time so your financial valuation stays synchronised without a nightly batch reconciliation.

Purchase order creation, supplier confirmation tracking, advance ship notice processing, and goods receipt with variance detection. Three-way match validation (PO, ASN, receipt) with discrepancy workflow for quantity and condition differences. Lot and serial number capture at receipt. Supplier performance tracking: on-time delivery, fill rate, and quality rejection rate.

Cycle count scheduling and management driven by ABC/XYZ classification: A-class items counted monthly, B-class quarterly, C-class semi-annually, with the schedule automatically generated based on each SKU's classification. The cycle counting scheduler assigns count tasks to operators by zone, generates pick-location count sheets, and tracks completion status so counts do not drift into a backlog.

Count entry via Zebra or Honeywell handheld scanners with barcode or RFID scanning reduces keystroke errors and speeds count entry compared to paper-and-clipboard workflows. RFID integration supports bulk count of entire pallets or bays without individual item scanning, reducing count time for high-volume locations by 70% or more. Variance detection compares entered quantities against system book quantities, flags variances above your tolerance threshold, and holds adjustments in an approval queue for authorisation rather than applying them automatically. Blind count option presents the operator with only location and SKU without showing system quantity, producing an unbiased count that is not anchored to the number the operator expects to see. Automatic recount trigger fires when variance exceeds your defined percentage, requiring a second independent count before the adjustment is posted. Dead stock identification surfaces SKUs with no movement in a configurable period, enabling disposal or markdown decisions before carrying cost accumulates further. Physical inventory count support for full wall-to-wall annual counts includes freeze scheduling, count sheet generation, and variance sign-off workflow.

Inventory performance reporting: stock turn by category, days of cover, slow-moving and dead stock identification, and shrinkage analysis. Demand-based reorder point calculation using historical sales velocity and supplier lead time. Replenishment recommendation reporting to support buying decisions. Custom reporting on the specific metrics your operation tracks.

Before building, we document your current inventory workflows, receipt, putaway, picking, packing, despatch, returns, and counting, and identify the gaps between current operations and the system you need. Inventory software that matches your actual workflows takes less user training and produces cleaner data than software that imposes a generic workflow.

Switching inventory systems requires migrating current stock quantities, product catalogue, supplier records, and historical transaction data. We plan the data migration during scoping, what to migrate, how to validate migrated data against source records, and how to manage the cutover so your operation doesn't have a gap period. Data migration is often where inventory system implementations fail.

Inventory management lives at the intersection of purchasing, warehousing, sales, and finance. We integrate the inventory system with your ERP for financial posting, your e-commerce platform for order management, your WMS for warehouse operations, and your supplier systems for EDI or API-based purchase order and shipment data exchange.

We test the inventory system against your real product catalogue and operational scenarios before go-live: receiving a multi-lot shipment, processing a sales order that depletes multiple lots, conducting a cycle count with variances, and generating a lot recall report. Testing against edge cases in your actual operation, not generic test scenarios.