Manufacturing ERP Bridge
Inventory OCR automation pipeline — bridging warehouse floor scanners to cloud ERP with real-time stock reconciliation.
OCR Inventory Pipeline
An automated pipeline that ingests barcode and label scans from warehouse floor handhelds, runs OCR correction and normalization, and upserts inventory records directly into the cloud ERP — eliminating manual data entry entirely.
- Multi-vendor scanner compatibility with raw image preprocessing (deskew, denoise, threshold)
- Tesseract OCR with custom warehouse lexicon for part numbers, lot codes, and serials
- Real-time upsert pipeline: scan → OCR → validate → PostgreSQL → ERP API
Key Outcome
Reduced inventory receipt processing from 4–6 hours per shift to under 90 seconds, with OCR accuracy exceeding 99.2% on first pass after lexicon tuning.
Real-Time Stock Reconciliation
Every scan event triggers an immediate reconciliation against expected stock levels in the ERP, surfacing discrepancies the moment they occur rather than days later during end-of-month audits.
- Per-SKU perpetual inventory counters synchronized with every confirm or reject action
- Delta engine that compares scanned quantities against open purchase-orders and transfer orders
- Dashboard alerts for over-receipts, short-picks, and mis-shipped items
Key Outcome
Slash month-end reconciliation from 3 full days to 45 minutes, and catch 94% of stock discrepancies within 60 seconds of the scan event.
Warehouse-to-Cloud Bridge
A resilient, queue-backed bridge that decouples the noisy warehouse floor network from the cloud ERP, buffering scans during outages and replaying them once connectivity is restored.
- Local PostgreSQL buffer with ack-based dequeue pattern — no scan is lost even if the ERP is down
- Idempotent ERP API client with retry, backoff, and dead-letter quarantine for malformed payloads
- Configurable sync cadence (real-time, batch-windowed, or manual-flush) per warehouse zone
Key Outcome
Achieved 99.97% scan-to-ERP delivery reliability over 6 months of production operation, including 14 hours of planned and unplanned network downtime.
Error Handling & Audit Trail
Every scan, every sync, every rejection is recorded in an immutable audit log with before/after snapshots, enabling trace-back from any ERP journal entry to the original warehouse-floor scan image.
- Immutable event-sourced log per SKU capture, including raw image hash and OCR confidence scores
- Dead-letter review UI for manual intervention on unprocessable scans
- Full lifecycle trace: image timestamp → OCR result → ERP journal ID → reconciliation status
Key Outcome
Reduced audit preparation time from weeks to minutes — a full trace from a year-end inventory adjustment back to the original scan takes under 5 seconds.