Custom-built inventory management that fits the production floor and reduces delivery errors

Before introducing the system, staff checked inventory manually and recorded quantities on documents or whiteboards. This method worked when product variety was limited, but as the business expanded, the risk of human error increased.

Inventory records did not always match the actual stock on hand. In some cases, products thought to be available were not actually in stock. There was also a risk of shipping the wrong product to customers. The company needed a reliable system that could provide accurate, real-time inventory information and support daily shipping operations.

Sanko Mold and Plastics (Thailand) initially considered packaged inventory software. However, packaged systems were costly and would have required the company to change its existing workflow to match the software.

PEGASUS was selected because TOMAS TECH could customize the system to fit the company’s actual operations. Through detailed interviews and repeated discussions, TOMAS TECH incorporated the functions the factory needed. Another key advantage was that the familiar Excel formats already used on site could be utilized within the program, making it easier for staff to adopt the new system.

PEGASUS manages the flow of goods from receiving to inventory control and shipping. For Sanko Mold and Plastics (Thailand), the system was configured around the following needs:

1. Reorder point control to prevent excess stock and stockouts
2. Product location control to support FIFO operations
3. Handheld terminal support for receiving and shipping
4. QR code control on KANBAN cards to identify product locations accurately

The company normally keeps five days of inventory. PEGASUS calculates reorder point quantities based on customer and product POs divided by operating days. When inventory falls below five days, the system shows an orange alert; when it falls below three days, it shows a red alert.

During shipping, the system displays what product should be shipped, how many units are required, and where the product is located. Operators can follow the instructions, go directly to the correct warehouse location, and confirm the item using QR codes and handheld terminals.

As a result, wrong-item deliveries have been greatly reduced. Inventory levels and product locations are now easier to see, which has improved both ordering work and production planning. The system has also been well received by factory staff because daily tasks have become clearer and easier to perform.

Sanko Mold and Plastics (Thailand) plans to expand the system beyond finished goods inventory to include material management and work-in-process management. The goal is to reduce the risk of stockouts and maintain appropriate inventory levels.

The company is also considering introducing inventory management for materials and parts at its factory in Vietnam. With around 300 items currently handled and more expected as new customers are added, the importance of a simple, practical, and sustainable inventory management system will continue to grow.

“Simple is best. A system must be easy for everyone to use, quick to operate, and sustainable. We appreciate TOMAS TECH’s flexible support, including fine adjustments after implementation. We would like to keep improving the system through daily operation so that everyone on the shop floor can use it with confidence.”