Case Study: ERP–WMS Transformation
End-to-end ERP and Warehouse Management System enabling real-time inventory, FIFO enforcement, QR traceability, dynamic pricing, and scalable warehouse operations from customer enquiry to dispatch.
Objective
Develop an ERP–WMS system to manage the complete order lifecycle from enquiry to dispatch, supporting warehouse expansion and scalable inventory controls.
- Develop an ERP–WMS system to manage the complete order lifecycle from enquiry to dispatch
- Support warehouse expansion from 30,000 to 100,000 sq. ft. with scalable inventory controls
- Enforce FIFO picking and QR-based traceability for bundles, cuts, and end-pieces
- Enable partial bundle sales and custom dimension cutting workflows
- Integrate daily metal price masters (Hindalco, Nalco) for accurate quoting
- Provide real-time dashboards, alerts, and ABC analysis for decision-making
Business Problem
The client relied on phone-based enquiry handling, ad-hoc purchasing, and Tally-only billing with no operational visibility into warehouse movements or volatile metal pricing.
- Customer enquiries handled via phone without real-time stock visibility
- Ad-hoc monthly purchasing with no safety stock or reorder logic
- Tally used only for billing with no operational visibility
- No tracking of putaway, picking, FIFO, or material movement
- Manual approval processes causing order delays
- High dispatch errors and returns during warehouse expansion
- No integration with volatile daily metal prices
Strategic Framework & Solution
Methodology: MoSCoW Prioritization & DMAIC (Lean Six Sigma) methodology was adopted to prioritize features, define gaps, and implement structured ERP–WMS improvements.
Discovery & Design
As-is process study across sales enquiries, purchasing, warehouse operations, production cutting, and dispatch. Identified gaps in stock visibility, FIFO, traceability, approvals, and pricing dependencies.
Design & FRD Finalization
Defined to-be ERP–WMS workflows covering enquiry-to-dispatch, purchase approvals, QR-based inward and putaway, FIFO picklists, production cutting, and end-piece handling using MoSCoW prioritization.
Build & Integration
Developed ERP modules for Sales, Purchase, Warehouse, Production, and Dispatch. Integrated QR scanners, weighbridge, daily metal price masters, and role-based dashboards with full audit logging.
Pilot & Validation
Pilot run in live warehouse with controlled users to validate GRN, QR bundling, FIFO picklists, cutting workflows, and dispatch accuracy. Exceptions and edge cases refined before scale-up.
Scale & Optimization
Organization-wide rollout supporting warehouse expansion from 30k to 100k sq. ft. Enabled KPI dashboards, exception alerts, ABC analysis, and continuous process optimization for scale and accuracy.
Solution Overview
The ERP-WMS solution integrates Sales, Purchase, Warehouse, Production, and Dispatch modules. It supports enquiry-to-quotation, sales order creation with approval controls, purchase workflows with ABC analysis, QR-based inward and putaway, FIFO picklists, production cutting workflows, and dispatch with billing and audit logs. Role-based dashboards and alerts provide real-time visibility across all operations.
Key Features Implemented
Before vs After Comparison
Deployment Impact & Business Value
Reduction in manual order processing and warehouse coordination effort
Real-time visibility of inventory, orders, and material movement
Improvement in picking accuracy and FIFO compliance
Reduction in dispatch errors, returns, and rework
Client Portfolio
Leading Metal Trading Enterprise
- Industries: Metals trading with volatile pricing, custom dimensions, FIFO requirements, and compliance-driven traceability
Industry Use Cases
Metals trading involves volatile pricing, custom dimensions (cuts from bundles), FIFO for expiry-prone stock, and traceability for quality/compliance. ERP-WMS suits by auto-pricing (NALCO/Hindalco feeds), handling partials/end-waste, QR for audits, and scaling amid supply chain flux — common for aluminum extrusions/sheets where 10–30% material becomes end-pieces without tracking.
SWOT Analysis
Strengths
- End-to-end enquiry-to-dispatch digitization
- QR-based traceability and FIFO enforcement
- Dynamic pricing integration with daily metal rates
- Scalable architecture supporting 100k sq. ft. expansion
Weaknesses
- Complex onboarding for warehouse floor staff
- Dependency on QR scanner hardware reliability
Opportunities
- Predictive inventory and demand planning
- Multi-location expansion with unified dashboards
- Automated supplier integration
Threats
- Volatile metal pricing affecting margin calculations
- Supply chain disruptions impacting inventory planning
Conclusion
The ERP-WMS solution eliminates manual silos, enforces precision in high-volume trading, and positions the firm for sustained growth with zero-visibility risks resolved through automation and insights.
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