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Case Study: Transforming Warehouse Operations with Mobile-Based WMS for a Logistics & Distribution Company

Introduction

A rapidly growing logistics and distribution company managing FMCG and consumer electronics products was facing operational inefficiencies across its warehouse network. Manual data entry, delayed stock updates, inaccurate pick-lists, and lack of real-time visibility were causing fulfillment delays and customer dissatisfaction. To overcome these challenges, the company implemented a mobile-based Warehouse Management System (WMS) designed to streamline end-to-end warehouse operations and strengthen last-mile delivery accuracy.

Business Challenges

Before the digital transformation, the warehouse teams struggled with:

1. Inefficient Inbound Management

  • GRN updates were done manually on paper.

  • Frequent mismatch between received quantity and system records.

  • Delays in making stock available for put-away.

2. Unoptimized Put-Away & Storage

  • Warehouse staff relied on guesswork for bin/location assignment.

  • High chances of misplacement and inventory discrepancies.

  • No real-time visibility into which racks were full or unused.

3. Error-Prone Picking & Packing

  • Manual pick-lists often led to incorrect item selection.

  • No scanning or validation process to reduce picking errors.

  • Packaging errors resulted in customer complaints and product returns.

4. Lack of Real-Time Inventory Accuracy

  • Inventory counts matched only during monthly audits.

  • Difficulties in responding to urgent customer orders due to unreliable stock visibility.

5. Disconnected Last-Mile Delivery Tracking

  • Delivery personnel had no digital proof of location or handover.

  • Inaccurate delivery logs created reconciliation challenges.

The company needed an integrated WMS that simplified day-to-day warehouse activities while providing complete visibility from inbound to dispatch.

Solution: Mobile-Based WMS Implementation

The logistics provider deployed a mobile-first WMS platform equipped with barcode scanning, digital workflows, and geo-fencing. The solution transformed operations across five warehouse locations.

Key Features Implemented

1. Streamlined Inbound Receiving

  • Staff used mobile devices to scan incoming shipments.

  • Auto-generated GRN ensured quick verification against purchase orders.

  • Damaged or missing items were instantly recorded through the app.

2. Smart Put-Away Recommendations

  • The WMS suggested optimal bin locations based on SKU type, size, and availability.

  • Warehouse staff received guided navigation to the correct rack.

  • Stock status updated in real time post put-away confirmation.

3. Barcode-Based Picking & Packing

  • Pickers received mobile pick-lists with real-time priority updates.

  • Barcode scanning validated each SKU to prevent errors.

  • Packing teams generated shipping labels and invoices directly from the app.

4. Real-Time Stock Visibility

  • Live dashboards showed accurate stock across categories, batches, and locations.

  • The WMS updated inventory after every movement—from receiving to dispatch.

  • Managers could track slow-moving, fast-moving, and near-expiry stock.

5. Geo-Fencing for Last-Mile Delivery

  • Delivery personnel were assigned geo-fenced zones.

  • Deliveries could be marked as complete only within the customer location radius.

  • Digital proof of delivery (with signature/photo) reduced disputes.

Implementation Approach

1. Warehouse Process Mapping

The operations team mapped all existing SOPs—receiving, put-away, picking, packing, dispatch—and customized the WMS to align with warehouse flow.

2. Training for Warehouse & Delivery Teams

Hands-on training sessions ensured all mobile users understood scanning workflows, task assignments, and exception handling.

3. Integration with ERP & Transport Systems

The WMS was integrated with the company’s ERP for purchase orders and sales orders, and with TMS for dispatch management.

4. Pilot Rollout & Scaling

A 3-week pilot at the central warehouse helped test and refine the setup before rolling it out to all regional hubs.

Results & Impact

1. 40% Faster Inbound Processing

Automated GRN and mobile scanning eliminated manual paperwork and reduced receiving time significantly.

2. 99.5% Picking Accuracy

Barcode validation ensured the right item was always picked, reducing returns and complaints.

3. 100% Real-Time Inventory Sync

Stock visibility was always up to date, helping managers plan replenishments accurately.

4. 30% Improvement in Order Fulfillment Speed

Optimized picking paths and accurate packing reduced turnaround time for customer orders.

5. Zero Delivery Location Disputes

Geo-fencing ensured delivery staff could only complete handovers at the right location, improving accountability.

Conclusion

The implementation of the mobile-based WMS transformed the logistics company’s warehouse operations into a digitally-driven, error-free, and highly efficient ecosystem. From inbound receiving to last-mile delivery, every step became traceable, faster, and more accurate. With improved inventory control, reduced errors, and real-time visibility, the business strengthened its supply chain reliability and elevated customer satisfaction.