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Industry not listed?Do you produce to order?

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Line-side replenishment is visual chaos

You run out of packaging or ingredients at the line and lose production hours while someone hunts for materials.

Book a call

Today, and with Frontlink.

Today

A 'runner system' with verbal requests, shout-based kanban, physical kanban cards, and Excel tracking that's always outdated.

With FrontlinkDigital kanban with min/max levels and replenishment task tracking
  1. Define line-side kanban bins per item with min/max levels and replenishment source locations.
  2. Operator taps 'bin empty' on the tablet (or scans a bin QR code), a replenishment task is created instantly for the warehouse team.
  3. Warehouse team sees pending replenishment requests with priority and location, fulfils them, and marks complete.
  4. Response time tracking links starvation downtime to replenishment latency, making the cost of slow replenishment visible.
  5. Start with the top 20 packaging items and expand, no need to model the entire warehouse from day one.
Time to value
1–2 weeks
Complexity
Medium
Works with machine counters
Partial

The problem

  1. Who feels it most

    Operators waiting for materials, warehouse runners, and supervisors managing ad-hoc replenishment requests.

  2. Why ERP / WMS doesn't solve it

    WMS sees warehouse locations but not consumption timing at the line. ERP MRP is too slow for hour-by-hour replenishment needs.

  3. How common is this?

    Inventory accuracy at the line-side level is an ongoing challenge. Line-side processes amplify discrepancies between system records and physical reality.

Business impact

  1. 'Starved line' downtime minutes, often the largest single downtime category
  2. Overtime and expediting from delayed replenishment
  3. Invisible cost: the correlation between replenishment latency and downtime is never measured

Solved by

  1. Warehouse and stockFrontlink knows per lot what is there, where it is and how long it is good for. The warehouse picks by shelf life, stock matches what was really used, and a lot can be traced in one click.

Frequently asked questions.

Who typically feels this problem?

Operators waiting for materials, warehouse runners, and supervisors managing ad-hoc replenishment requests.

Why doesn't an ERP or WMS system solve this?

WMS sees warehouse locations but not consumption timing at the line. ERP MRP is too slow for hour-by-hour replenishment needs.

How does Frontlink solve this?

Digital kanban with min/max levels and replenishment task tracking. Define line-side kanban bins per item with min/max levels and replenishment source locations. Operator taps 'bin empty' on the tablet (or scans a bin QR code), a replenishment task is created instantly for the warehouse team. Warehouse team sees pending replenishment requests with priority and location, fulfils them, and marks complete. Response time tracking links starvation downtime to replenishment latency, making the cost of slow replenishment visible. Start with the top 20 packaging items and expand, no need to model the entire warehouse from day one.

How quickly does it deliver value?

Typical time to value: 1–2 weeks. Implementation complexity: Medium.

Which process takes you the most time?

Book a 30-minute call. We look at your own examples together.

Book a call