Explore how Ciphernutz automated the daily stock reporting in Raw Material Handling System (RMHS) by leveraging automation for real-time inventory visibility.
Client Overview
The Problem
As material volume and production demands grew, the facility's manual reporting processes began to crack under pressure. What once took two staff members a manageable amount of time had ballooned into a 4-6 hour daily effort while still producing inaccurate results.
The staff were generally losing critical operational hours, daily, in cross-referencing handwritten intake logs against the master material code spreadsheets. The manually reconciling weight discrepancies, and rebuilding the same daily report from scratch every single shift ultimately delayed timelines.
By the time the report reached plant management, the data was already stale and several degrees less actionable.
During peak intake hours (first 90 minutes), disconnected systems for material intake and consumption caused reporting delays. As a result, key reports like the Daily Stock Report lagged by 3-5 hours behind real-time operations.
With 80+ material codes, staff had to manually match each entry, making the process slow and error-prone-especially during high-volume intake periods.
Decisions were based on outdated reports or estimates, leading to over-ordering and unexpected stock-outs due to lack of live inventory insights.
Manual entries caused 12-15% discrepancies between actual and recorded stock, requiring frequent audits and increasing operational costs.
The Solution
Ciphernutz designed and deployed an end-to-end automated data pipeline to enable manual intervention from the RMHS daily stock reporting cycle.
We also replaced hours of fragmented spreadsheet work with an intelligent, scheduled workflow that ingests raw material data, maps it against the master code database.
Thus, after validating every entry, it delivers a clean and finalized stock report automatically, especially right before each shift begins.
Deliverables
The system connects to the facility's existing infrastructure to capture raw material arrivals and consumption in near real-time without manual intervention. This automated ingestion layer reliably handles over 200 daily transactions using built-in retry logic to ensure complete data integrity.
An intelligent mapping engine automatically cross-references incoming entries against the master database, flagging mismatched records for human review. The version-controlled master database ensures that any updates to material codes are instantly reflected in future reports, too.
Once all entries are validated, the system compiles the daily stock report in a standardized format to match with existing templates. This report is automatically generated thirty minutes before each shift and delivered directly to key personnel without needing manual formatting.
A live dashboard provides managers with a continuously updated view of stock levels, consumption trends, and incoming materials. Visual alerts trigger when materials fall below safety thresholds, empowering the procurement team to make proactive decisions without waiting on reports.
Results
The RMHS Daily Raw Material Stock Report automation delivered measurable operational improvements within the first two weeks of going live. By eliminating manual data mapping and automating report generation, the facility freed up significant staff time. They also reduced recurring data discrepancies, and gave plant managers the real-time visibility they needed to make faster, more confident operational decisions.
78%
Increase in overall reporting speed
92%
Reduction in data entry and mapping errors
65%
Decrease in administrative workload for operations staff
3x
Supply chain visibility
100%
On-time report delivery
Innovation moves fast, and so do we. Our approach reduces complexity, accelerates decision-making, and helps businesses build, launch, and scale software faster.
“Excellent end-to-end experience with Ciphernutz. They delivered a best-in-class product, and the entire process from start to finish was absolutely fantastic.”
Jake Adams
Head of Product
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