Cross Platform Inventory App with Barcode Scanning and Offline Sync
A manufacturing company needed an internal inventory app that worked on both iOS and Android devices used on the floor. We built a cross platform solution with barcode scanning, offline first workflows, and a reliable sync layer that reduced inventory errors and improved cycle count speed.
Confidential engagement. NDA available upon request.
43%
Faster Cycle Counts
58%
Fewer Inventory Errors
0.3%
Sync Conflict Rate
9
Weeks to Rollout
About the Client
Industry
Manufacturing
Company Size
300 to 600 employees
Background
A manufacturing operation with multiple warehouses. Inventory counts were manual and error prone, and existing tooling did not work reliably on mobile devices in low connectivity zones.
Operational Pain Points
Manual processes and data delays
Counts were recorded on paper then entered later, creating delays and errors.
Connectivity gaps on the warehouse floor
Devices frequently lost connectivity, requiring offline mode for all critical actions.
Device fragmentation
The company used a mix of iOS and Android hardware and needed consistent behavior across both.
Data integrity concerns
Conflicts and duplicates had to be handled predictably to avoid inventory drift.
The Mission
Deliver a cross platform inventory app that supports barcode scanning, works offline, syncs reliably, and reduces error rates in operational workflows.
How We Approached It
01. Workflow mapping
Week 1 to 2- Process mapping for receiving, picking, and cycle counts
- Offline first data model and sync rules
- Hardware and barcode scanning requirements
- API contract alignment with inventory system
02. Build
Week 3 to 7- Cross platform UI build with shared logic
- Barcode scanning and validation rules
- Offline queue, retry logic, and conflict handling
- Performance testing on low end devices
03. Rollout
Week 8 to 9- Pilot in one warehouse with telemetry
- Training and feedback sessions
- Staged rollout to additional sites
- Post rollout stabilization support
Vulnerabilities Discovered
0
CRITICAL
1
HIGH
2
MEDIUM
1
LOW
Duplicate submissions during reconnect
Offline retries could submit the same count multiple times without idempotency support.
Offline retries could submit the same count multiple times without idempotency support.
Scan validation needed stronger guardrails
Certain item formats required stricter validation to prevent wrong item associations.
Certain item formats required stricter validation to prevent wrong item associations.
Large lists impacted performance
Long pick lists required pagination and caching to remain responsive.
Long pick lists required pagination and caching to remain responsive.
Inconsistent device permissions prompts
Camera and storage permission flows required clearer user guidance.
Camera and storage permission flows required clearer user guidance.
How We Fixed It
Offline sync hardening
Added idempotency keys, retry backoff, and server reconciliation for counts and adjustments.
Barcode workflows
Implemented scanning flows with validation and clear error recovery steps.
Performance improvements
Introduced pagination and caching so lists remained fast on older devices.
Measurable Outcomes
The app reduced manual work and improved inventory accuracy, while keeping workflows reliable under low connectivity conditions.
43%
Faster Cycle Counts
58%
Fewer Inventory Errors
0.3%
Sync Conflict Rate
90%
Adoption in First Month
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