The team counted carefully and kept a record. The slow part was entering it: several hundred parts typed in one row at a time, where a number in the wrong row stayed wrong, into a sheet that could not say when a part would be needed next. Below is the same week, before and after.
What
Before · paper and spreadsheet
After · Inventory Tracker
Counting the shelf
BeforeDone by hand on paper, in no fixed order
AfterStill done by hand on paper, which is faster than counting at a screen. The sheet is printed in the same order as the shelf
Getting the numbers in
BeforeTyped into Excel one part at a time, several hundred rows; a number in the wrong row was hard to spot
AfterThe counted sheet is photographed and uploaded, and the program takes the numbers off it and saves them as a new dated count, keeping the earlier ones
How fast a part is used
BeforeOne formula, applied to every part the same way
AfterWorked out per item from the difference between two counts
Christmas
BeforeOne average for the whole year, with nothing extra for Christmas
AfterFour paces per item, each measured from that item's own history: Christmas, Mother's Day, January to March, and the rest of the year
When it runs out
BeforeNot shown on the sheet
AfterA date, projected day by day from today's stock at that item's current pace
When to order
BeforeDecided from the totals on the sheet
AfterAn order by date per item, worked back from the run out date using that supplier's own lead time
How many to buy
BeforeDecided by the person ordering
AfterA quantity on the row, sized to cover the lead time and the pace
What is safe
BeforeEvery row looked the same, urgent or not
AfterThe home screen lists only what needs ordering today
Trusting the answer
BeforeCheck the spreadsheet formula by hand
AfterEvery verdict opens into numbered steps with the arithmetic shown, in the order the program decided it
The three big orders a year
BeforeJanuary, after Mother's Day and before Christmas, each one worked out line by line from a sheet of totals that could not say how long a part would last
AfterBuilt from the same counts: a quantity per item that carries it to the next big order, with the rows that cannot wait for it listed separately
How long a delivery takes
BeforeKnown by the people who had ordered before, and allowed for by hand
AfterEstimated per supplier from the delivery log, subtracted from the run out date to give the last safe day to order, with extra weeks added across the Chinese New Year break
Deliveries arriving
BeforeAdded to the sheet by hand, as another row to find and edit
AfterReceiving is a step in the program, and an order on its way counts toward future stock