Case Study: How an efficient tailor-fit Warehouse Management Solution can Streamline Operations and Optimize Manufacturing Order Processing

Complex manufacturing processes often have unique requirements and intricacies that off-the-shelf WMS may not fully address, which can result in delays, errors, production interruptions, and inventory management problems.

Efficient manufacturing order processing is crucial for e-commerce retailers, enabling effective inventory management, streamlined production, and the ability to meet customer demands promptly. By integrating manufacturing processes with warehousing, retailers can ensure timely production, maintain accurate inventory levels, and minimize both stockouts and overstocking.

Challenge:

One of our customers who are specialized manufacturer & retailer of personal cosmetics and handcraft products had a particular challenge with complicated manufacturing process alongwith inefficient inventory system resulting in delayed orders, creeping errors, and overwhelming returns.

Fractional inventory bundles posed challenges in accurately identifying product inventory with their existing WMS. Additionally, obtaining print labels for specific product items and dealing with inaccuracies slowed down their packing, leading to delays and errors in their complex business processes.

The lack of a customized solution led to difficulties in tracking the status of manufacturing work orders, ultimately impacting their ability to make informed decisions, and affecting their business significantly. These looming issues put their entire operation at risk, leading to a significant drop in customer satisfaction levels.

Solution:

A tailored manufacturing solution was devised, integrating a streamlined system for creating production orders and seamlessly linking raw materials and consumables to fractional product quantities. Additionally, an optimized pick and pack procedure was established, resulting in synchronization of finished products with manufacturing orders to enhance inventory management efficiency, along with strengthening control over scrap management.

We customized the product structure to their business model, including, multilevel product configuration design, and back-orderable inventory estimation assistance for manufacturable products.

Our WMS also offered a return order management solution, aiding in organized handling of returns, enabling customers to analyze and minimize returns by enhancing the restocking process with adaptable return reasons.

Thus, leveraging our in-house IT team’s skills and years of experience, TEJAS deployed pre-built functionalities alongside customized adaptations, prioritizing scalability, and flexibility to optimize detailed manufacturing workflows, remove bottlenecks, and enhance overall efficiency.

Capability enhancements:

The implementation of efficient customization and sophisticated capabilities for this customer has resulted in;

• a substantial improvement in label printing speed when compared to the previous process.
• significant reduction in fulfilment times by enabling bulk printing of pack sheets and labels, along with print automation.
• besides enabling error-free label printing it also eliminated fulfilment issues from manual printing tasks.

Result:

- Achieving 87% accuracy in selling inventory to marketplaces.

- Witnessing 45% increase in sales across all products.

- Experiencing 68% increase in back-orderable manufactured products.

- Achieving 67% increase in completion of the packing process.

- Realizing 84% reduction in returns.

Summary:

TEJAS WMS, featuring custom pick wave batching logic, not only supported efficient picking but also ensured accurate packing, greatly benefiting the customer.

With our tailored end-to-end automation solution, catering to customer requirements, streamlined manufacturing order processing along with order tracking and return workflows.

In essence, with TEJAS customized warehouse management solution, we were able to bring order, streamline processes, and restore efficiency replacing frustration with effectiveness.

For more information contact;

Prabhu Vasudevan

Vice President

prabhu@tejassoftware.com

https://www.tejassoftware.com/