Effective stock control is the backbone of any efficient manufacturing operation. Yet, many businesses still fall into common traps that lead to costly errors, stockouts or overstocking, all of which can disrupt production schedules, reduce customer satisfaction and shrink profit margins.
At Hellenic Systems, we’ve worked with manufacturers across the UK to implement smart, scalable systems that eliminate inefficiencies and bring clarity to the stock control process. Here are some of the most common mistakes we see – and how you can avoid them with FOPS8, our Factory Order Processing System.
1. Relying on manual processes
Spreadsheets, paper logs and outdated legacy systems might have worked in the past, but they can’t keep up with the demands of today’s complex supply chains. Manual input is time-consuming and error-prone, often leading to discrepancies between what’s recorded and what’s actually on the shelves.
The fix: FOPS8 automates inventory tracking across your factory, from goods-in to dispatch. With real-time stock visibility, barcode scanning and mobile device support, every movement of materials is captured and logged. You gain full traceability without the manual effort.
2. Poor location control in the warehouse
Without clear location tracking, staff spend unnecessary time locating items – or worse, dispatch the wrong product altogether. Misplaced goods and inefficient picking routes cause delays, errors and frustration.
The fix: FOPS8 supports precise stock location control, enabling you to track materials by bin, rack, or zone. Its flexibility allows you to map your factory layout and storage systems within the software, ensuring production orders are directed to the right stock, in the right place, at the right time.
3. Lack of integration with production or sales systems
Disjointed systems often mean your stock levels aren’t aligned with production schedules or customer demand. This can lead to overproduction, missed orders or last-minute panic buying.
The fix: FOPS8 connects your stock control with live production planning, sales order processing and demand forecasting, all within one system. This end-to-end visibility enables you to make smarter, faster decisions based on accurate, real-time data.
4. No real-time stock visibility
If you’re relying on end-of-day reports or manual audits to understand your stock position, you’re making decisions based on outdated information.
The fix: FOPS8 delivers real-time stock data across your entire operation. Whether you’re tracking raw materials, work-in-progress or finished goods, you’ll have live insights at your fingertips, accessible from desktop, tablet or mobile.
5. Overcomplicating the system
Trying to fix stock problems with a patchwork of disconnected tools often backfires, leading to overly complex processes, staff confusion and even more mistakes.
The fix: Simplicity is built into FOPS8. The system is configurable to match your processes and workflows, not the other way around. With an intuitive user interface and powerful automation, it brings everything together in one centralised platform that your team can quickly adopt.
Ready to take control?
Whether you’re running a fast-paced warehouse, a complex production line, or both, FOPS8 can help you avoid the most common stock control mistakes.
Chat to us today about how FOPS8 can transform your operations from end to end.
