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Predictive Parts Replenishment

Predict. Prioritize. Prevent Line Stoppages.

TTLS (Time-To-Line-Stop) is a SQUEAKS® module
that continuously evaluates material demand and production risk to help teams prioritize the deliveries that matter most.

Rather than treating every parts request equally, TTLS identifies which requests are becoming most critical.

PREVENT LINE
STOPPAGES
GAIN REAL-TIME
VISIBILITY
MAXIMIZE
THROUGHPUT
OPTIMIZE LABOR
& RESOURCES

From Requests to
Production Protection

REQUEST

Material Need 
is Captured
CALCULATE RISK

TTLS Calculates
Time-To-Line-Stop
PRIORITIZE

Requests are Ranked by
Production Risk
DELIVER

Material Handlers Complete the Most Critical Deliveries First
MEASURE & IMPROVE
SQUEAKS captures the response and creates Response Intelligence.

From Predictive Risk to Response Intelligence

SQUEAKS captures what happened after every request: who responded, when it was claimed, how long delivery took, skipped or hot calls, workload, and outcome.

Live dashboards and historical reporting give management a baseline for improving response productivity, staffing, equipment utilization, and material-flow performance.

The Challenge

When multiples need parts at the same time, it's hard to know which delivery matters most.

Without real-time
prioritization, manufacturers experience:

LINE STARVATION

LOST PRODUCTION

EXPEDITED DELIVERIES

EXCESS INVENTORY

OVERTIME COSTS

 REDUCED THROUGHPUT

SAFETY INCIDENTS

How TTLS Helps

Prevent Line Stoppages

Identify high-risk situations early and deliver
parts before production is impacted.

Maximize Throughput

Keep production moving and improve attainment with reliable material availability.

Prioritize What Matters Most

Automatically rank requests so teams focus on
the work that has the greatest impact.

Improve Labor Utilization

Do more with less by directing resources where
they are needed most.

Increase Visibility

Gain real-time insights into risks, requests, performance and potential disruptions.

Key Capabilities

PREDICTIVE
TIME-TO-LINE-STOP

Continuously evaluates consumption, inventory, schedules, and demand to predict when a line could run out of material.
DYNAMIC
PRIORITIZATION

Requests are ranked in
real time based on risk so
the right deliveries
happen first.
REAL-TIME
WORK QUEUES

Material Handlers

receive prioritized assignments with risk, location, and
time-to-line stop.
TEAM LEADER INTERVENTION

Supervisors can mark
HOT, cancel requests,
pause cancellations,
and monitor team performance.
CLOSED-LOOP REPLENISHMENT

Automatically trigger replenishment to intermediate locations and keep material flowing.
ANALYTICS
& ALERTS

Dashboards and alerts provide insight into risks, performance and
critical events.

Turn Better Prioritization Into Economic Value

When teams know which delivery matters most and when, they can begin to operate with fewer unnecessary trips, less searching and “sharking,” and better utilization of Material Handlers and forklifts.

Over time, TTLS and SQUEAKS can help management answer questions such as:

  • Are we using more Material Handlers than the workload requires?

  • Could fewer forklifts support the same number of parts calls?

  • Are resources consistently responding to the highest-risk requests first?

  • How often are calls becoming hot, skipped, or reaching line-stop risk?

  • Is response productivity improving over time?

Measurable Business Outcomes

Reduce
Material Related Downtime
Improve Production Attainment
Increase Throughput
Improve Labor
& Resource Utilization
Lower
Inventory Requirements
Enhance Safety
& Operational Performance

How To
Get Started:

Your time is valuable, so we only ask for 15 minutes…

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Book a 15 Minute Discovery Call

Schedule a Demo

Get Started in Your Plant

Know Sooner. Act Faster.

Contact Us Today.

Office: 502.423.0999
Toll Free (USA/Canada): 1.800.407.0458
International: 1.813.882.5809

8016 Vine Crest Avenue
Louisville, KY 40222

 

© 2026 IGear, LLC 

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