Supply Chain & Export Logistics Case Study

Optimizing Warehouse Stock WIP Tracking and Reducing Picking Errors by 92% for an Exporter in Sriperumbudur

Background & Challenge

Indo-Global Exports faced delays in picking and shipping orders. Manual tracking in a 50,000 sq ft warehouse led to misplaced inventory, picking errors, and late shipments.

Our Solution Approach

We designed a web-based Warehouse Management System (WMS) built on Next.js, Express, and PostgreSQL, featuring barcode-guided picking, live slot tracking, and automated stock triggers.

Overview

In international supply chains, order fulfillment speed and shipment accuracy determine market competitiveness. Indo-Global Exports Private Limited operates a 50,000 square foot consolidation and packaging facility in the industrial manufacturing hub of Sriperumbudur, Chennai. Before upgrading their operations, the company tracked inventory using paper logs and memory.

Warehouse workers manually searched aisles for raw materials and products, spending an average of 25 minutes per lookup. This inefficiency led to picking errors, delayed shipping containers, and late-delivery charges. Yamee Cluster built a custom, barcode-integrated Warehouse Management System (WMS) that automated stock locating and picking, reducing picking errors by 92% and improving replenishment speed.

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The Challenge

Manual warehouse tracking introduced several operational challenges:

  • Misplaced Inventory: Workers misplaced product boxes, resulting in duplicate purchases and write-offs.
  • Frequent Picking Errors: Manual orders led to incorrect parts being packed, causing customer returns.
  • Slow Replenishment Cycles: Re-ordering stock took days, leading to stockouts of popular shipping lines.
  • Inefficient Space Use: Without automated planning, warehouse floors were crowded, lowering storage capacity.

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Requirements

The WMS system was engineered to deliver the following capabilities:

1. Dynamic Bin Location: Mapping the 50,000 sq ft floor plan into digitized racks and rows.

2. Barcode Scanner Integrations: Software that connects to mobile terminals to scan inventory codes.

3. Automated Pick Paths: Algorithms that calculate the shortest walking path for picking items.

4. Real-time Stock Alerts: Alerts to notify procurement when inventory falls below minimum safety stock.

5. Carrier Integration: Automated generation of shipping labels and custom document templates.

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Architecture

Yamee Cluster engineered a secure, mobile-first warehouse architecture:

  • Frontend App: Mobile PWA built on Next.js, styled with Tailwind CSS, and optimized for industrial handheld scanners.
  • Backend API: Secure Node.js microservice running on Docker containers.
  • Database: PostgreSQL database instance designed to process concurrent barcode scans without lag.
  • Integrations: Webhook services to connect shipping carrier systems and inventory databases.
  • Security: Closed intranet network configuration to protect database access on-site.

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Execution

The WMS implementation was completed over a 12-week schedule:

  • Phase 1: Facility Audit (Weeks 1-2): Audited warehouse layouts, aisle designations, and packing workflows.
  • Phase 2: Database Schema & API Setup (Weeks 3-5): Modeled the warehouse map and developed stock tracking APIs.
  • Phase 3: Handheld Scanner Software (Weeks 6-8): Developed the mobile PWA and tested barcode scan processing.
  • Phase 4: Path Optimization & Labels (Weeks 9-10): Implemented pick-path routing and carrier label generation.
  • Phase 5: Staff Training & Cutover (Weeks 11-12): Labeled warehouse slots, trained staff on scanners, and launched the system.

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Timeline

The project moved through the following phases:

  • Week 1-2: Requirements mapping, warehouse layout digitization, and database design.
  • Week 3-4: API development, database optimization, and barcode integration coding.
  • Week 5-7: Mobile scanner frontend and pick-path routing setup.
  • Week 8-9: Shipping label and document engine development.
  • Week 10-11: System pilot runs with selected picker teams and adjustments.
  • Week 12: Complete warehouse implementation and catalog migrations.

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Outcome

The custom WMS system transformed warehouse operations:

  • Instant Location Lookups: Stock lookup times fell from 25 minutes to under 45 seconds.
  • 92% Fewer Picking Errors: Barcode verification at picking eliminated incorrect product shipments.
  • Faster Stock Replenishment: Re-ordering times dropped from 5 days to 1.5 days.
  • 20% Storage Gain: Optimized slotting rules improved warehouse floor space utilization.

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Business Impact

The operational gains improved overall supply chain profitability:

  • Zero Late Container Penalties: Faster picking ensured all export containers shipped on schedule, avoiding fees.
  • Lower Inventory Write-offs: Misplaced stock was eliminated, reducing inventory loss by 95%.
  • Greater Team Efficiency: Picker staff completed 30% more shipments daily with less physical fatigue.

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FAQ

What barcode scanners are supported by the mobile PWA?

The application is compatible with Android-based Honeywell, Zebra, and standard Bluetooth-connected scanners.

How does the system handle inventory adjustments?

Authorized supervisors can adjust stock counts directly through the manager portal, logging details for compliance audits.

Can the WMS operate without internet access?

The local server hosts a local copy of the database, ensuring operations continue even during internet outages.

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CTA

Are you looking to optimize warehouse operations and reduce order picking errors? Contact Yamee Cluster to learn more about our custom warehouse management solutions.