Manufacturing teams operating across multiple facilities often struggle with manual inventory replenishment processes that lead to stockouts, redundant work, and reactive decision-making. A common pattern we see is that legacy ERP systems rely heavily on individual judgment to trigger replenishment, creating inconsistencies and firefighting across sites.

This Customer Pattern Insight reflects how teams use E-Kanban automation to standardize replenishment, reduce manual effort, and improve visibility into future inventory needs, while maintaining flexibility for ERP integration.

The Challenge

Manual replenishment creates inefficiencies and frequent stockouts.

In multi-facility manufacturing environments, inventory replenishment is often managed through manual triggers within legacy ERP systems. This approach depends on individuals monitoring inventory levels and initiating replenishment actions, which leads to inconsistent execution, duplicated effort, and missed demand signals.

Before automation, teams commonly experience stockouts as frequently as every other day. The lack of early visibility into intersite demand forces operations teams into reactive mode, spending time addressing shortages instead of planning proactively.

The Approach

Automating replenishment with E-Kanban.

Teams implement E-Kanban to automate replenishment triggers across facilities. Instead of relying on individuals to monitor and act, demand signals are generated systematically, providing earlier and more accurate visibility into inventory needs.

This approach reduces manual intervention, minimizes firefighting, and creates a more predictable, analytics-driven process.

The Impact

From reactive inventory management to proactive planning.

Teams report fewer stockouts, reduced manual work, and more productive operational conversations. In this example pattern:

• Stockouts that previously occurred every other day were significantly reduced
• Roughly 6 hours per week were saved by eliminating manual reordering tasks
• Inventory discussions shifted from reactive issue resolution to analytics-driven decision-making

Implementation Pattern

E-Kanban is implemented across multiple facilities and adopted by a small group of users before scaling, with ERP integration often planned as a next step.

Ultriva E-Kanban automates intersite replenishment, improves inventory visibility, and supports proactive operational planning.