SteelCore Industries — AI Inventory Management Across 3 Warehouses

 | CHALLENGE
 SteelCore Industries operated 3 manufacturing facilities and had no real-time visibility into inventory across sites. Stock counts were done weekly by hand. Purchase orders were raised manually based on gut feel. Stockouts on critical components shut down production lines, costing $12,000+ per hour in lost output. Overstock on slow-moving items tied up hundreds of thousands in working capital.
 
 SOLUTION
 FLYZEO deployed an AI inventory agent that monitors stock levels across all 3 facilities in real time, predicts demand based on production schedules and historical consumption patterns and raises purchase orders automatically within approved parameters.
 
 Key automations delivered:
 - Real-time inventory monitoring across all 3 facilities — updated every 15 minutes from barcode scan data
 - AI demand forecasting model trained on 18 months of production and consumption data
 - Automatic PO generation for approved suppliers when stock falls below dynamic reorder points
 - Cross-facility transfer order suggestions when one site has surplus and another has deficit
 - Weekly inventory position report with variance analysis delivered to the operations director
 - Supplier lead time tracking — reorder points automatically adjusted as lead times change
 
 TECH STACK: n8n, OpenAI GPT-4o, Custom ERP Connector, Barcode Scanner Integration, Google Sheets, Email API
 
 TIMELINE: Deployed in 14 days
 
 RESULTS
 - Zero production line stoppages due to stockouts in 6 months post-deployment
 - 60% reduction in inventory carrying costs through better demand-driven restocking
 - 8 hours per week of manual stock counting and PO work eliminated
 - 3-site inventory visibility available for the first time in company history
 - Supplier performance tracking enabled better renegotiation of 3 major contracts