From Spreadsheets to Real-Time Inventory Tracking
A mid-sized manufacturing company with 85 employees and three warehouse locations was struggling to keep accurate inventory counts. Their existing process relied on shared Excel files, manual data entry, and weekly physical counts.
🔴 The Challenge
Inventory discrepancies were costing the company time and money. Floor managers at each location maintained their own spreadsheets, which were emailed to the central office every Friday. By the time the data was consolidated, it was already outdated.
- No real-time visibility into inventory across locations
- Manual data entry leading to frequent errors
- Weekly reporting lag causing over-ordering and stockouts
- No mobile access for floor staff doing physical counts
🟢 The Solution
We built a custom Power App that replaced the spreadsheet process entirely. Floor staff use tablets to scan items, update counts, and log incoming shipments — all in real time. The data flows into a central Dataverse database that all three locations share.
We paired the app with Power Automate flows that send automatic alerts when inventory drops below minimum thresholds, notify purchasing when reorder points are triggered, and generate consolidated weekly reports automatically.
The team also got a Power BI dashboard showing real-time inventory levels across all locations, reorder status, and historical trends.
📊 The Results
| Metric | Before | After |
|---|---|---|
| Inventory accuracy | ~82% | 97%+ |
| Weekly reporting time | 6+ hours | Automated (0 hours) |
| Stockout incidents | 8-10/month | 1-2/month |
| Over-ordering waste | ~$4,200/month | ~$800/month |
The system paid for itself in less than three months. Floor staff adopted the app within two weeks, and management now has confidence in their inventory data for the first time.