Warehouse Management System Development

Receiving workflows that capture inbound shipments against purchase orders, record quantity and condition, apply QC hold processes where required, and generate putaway tasks directed to the correct location based on your slotting rules. Supplier ASN (Advance Ship Notice) matching validates inbound carton counts before the dock door opens, reducing discrepancy resolution time. GS1-128 barcode labels and SSCC (Serial Shipping Container Code) scanning confirm pallet and carton identity at the point of receipt. Blind receiving mode is available for operations that verify supplier accuracy without pre-populating expected quantities.

Directed putaway uses a slot scoring algorithm that factors product velocity (A/B/C classification), weight, cube, temperature zone requirements, and current location capacity to assign the optimal bin position for each received SKU. Cross-docking routes inbound goods directly to outbound staging when open orders exist, bypassing putaway entirely. Putaway task confirmation via RF handheld terminals -- Zebra MC3300 and TC52 are standard integrations -- ensures every product lands in a known, confirmed location from the moment it arrives.

Location master built to match your physical warehouse -- aisles, bays, levels, and bin positions, modelled down to the individual pick face slot. Every SKU tracked at location level with quantity on hand, quantity allocated to open orders, lot number, expiry date, and serial number where applicable. Slotting rules define which product classes belong in which zone: fast-moving A-velocity SKUs in the primary pick aisle, B-velocity in secondary, and C-velocity in deep bulk storage. Slotting review reports surface SKUs whose observed velocity no longer matches their current slot assignment so the operations team can rebalance periodically.

Mixed-SKU location support handles operations that cannot dedicate one location per SKU without running out of bin positions. Location capacity management tracks available space in volume (cubic metres) or pallet positions so putaway tasks are never directed to a location that cannot physically accept the unit. Transfer tasks generated by the system consolidate slow-moving stock and recover premium pick-face locations for faster-turning product. RFID reader integration -- fixed tunnel readers at dock doors or handheld RFID -- is available for operations with RFID-tagged inventory or reusable assets such as totes and pallets. Integration with SAP WM/EWM and NetSuite WMS is available for sites that run a host ERP alongside the WMS.

Wave planning groups open orders into pick waves based on shipping carrier cutoff times, service level (next-day, standard, economy), and order priority. Wave release management controls when each wave is sent to the floor, allowing the warehouse manager to release waves progressively as labour becomes available rather than flooding the pick face with tasks simultaneously.

Pick strategy selection is configurable per wave: discrete picking assigns one order per picker from start to finish; batch picking groups multiple orders per picker to reduce travel distance when order profiles are small; zone picking assigns pickers to fixed aisle zones with orders consolidated at a merge point; cluster picking sends a picker with a multi-tote cart to collect several orders in a single aisle pass. Directed pick tasks are delivered to Zebra RF handheld terminals (MC3300 for ambient, TC52 for mobile-intensive environments) following an optimised path through the pick face.

Pack station workflows present the correct carton size recommendation based on order cube, capture weight for carrier rate shopping, and generate packing slips automatically. Shipping label generation integrates with the EasyPost API to produce carrier-compliant labels for parcel carriers (UPS, FedEx, USPS, DHL) and LTL carriers in a single interface, without requiring separate logins to each carrier portal. Ship confirmation with tracking number is pushed back to the originating order management system or Shopify/Magento store in real time. Conveyor and sorter system integration via PLC Modbus TCP is available for operations with automated sortation equipment that needs task triggers from the WMS.

Cycle counting programs divide your warehouse inventory into count groups organised by location zone, product velocity class, or product category, then schedule a small number of location counts each working day. Over a rolling four-to-eight-week period, every location in the warehouse is counted at least once without requiring a warehouse shutdown. This approach keeps inventory accuracy metrics current rather than letting shrinkage and mis-picks accumulate until a full physical stocktake reveals the extent of the problem.

Count tasks are assigned to pickers via RF handheld terminal. The counter scans the location barcode, counts what is physically present, and the WMS compares the result to the system quantity on hand. Variance threshold configuration determines when a minor discrepancy is recorded without action versus when a significant variance triggers a supervisor blind recount before the system quantity is adjusted. Count history and variance trend reporting identify specific locations, product categories, or shifts with recurring accuracy problems so the root cause -- a receive error, a mis-sort at the pack station, or a labelling issue -- can be addressed rather than just corrected. Shrinkage rate is tracked as a separate metric from pick errors so the source of inventory loss is distinguishable. Full stocktake mode supports annual counts or client-requested full physical inventories for 3PL operations where clients have contractual accuracy guarantees.

RF handheld terminal integration covers the full range of WMS task types: receiving, putaway, replenishment, pick, pack, cycle count, and transfer. Supported hardware includes Zebra MC3300 (warehouse-grade handheld for heavy-use environments) and TC52 (touch-based for operations that need a faster scan cycle). Vehicle-mounted terminals for forklift operators handling pallet putaway and bulk picking are also supported. All terminal types connect to the WMS server over Wi-Fi using a browser-based or thin-client interface, which eliminates software update dependencies on the device.

Barcode validation at every task step confirms the correct product identity (GS1-128 barcodes, SSCC labels on pallets) and the correct bin location before the system accepts the task completion. A picker who scans the wrong location or the wrong product gets an immediate rejection on the screen rather than completing a mis-pick that the system records as correct. RFID reader integration -- fixed portal readers at dock doors for pallet-level RFID, or handheld RFID for individual item tracking -- is configured for operations where RFID tag density justifies the infrastructure cost. Asset tracking for reusable totes, cages, and pallets is a common secondary use case for RFID in WMS environments. Scan data is logged with timestamp, user, and location for every task event, providing a complete audit trail for dispute resolution and accuracy reporting.

Billing module for 3PL operations that charge clients based on warehouse activity logged in the WMS. Storage charges are calculated at the end of each billing period by pallet position occupied, cubic metre of space used, or SKU count stored -- whichever unit the client contract specifies. Handling fees are charged per inbound receipt line, outbound order line, carton picked, or order shipped, pulled directly from the WMS transaction log rather than requiring manual compilation. Activity-based charges for value-added services -- labelling, kitting, reworking, and quality inspection -- are recorded as billable activity codes against the relevant client and tallied per period.

Rate card management allows different rate structures per client, with volume discount tiers, minimum monthly charges, and contract-specific billing rules. The billing engine runs a period close at the end of each billing cycle and produces a line-item report per client showing all billable events, quantities, applied rates, and total charges. Client portal access gives each client a real-time view of their current stock levels, inbound and outbound activity log, and accrued billing for the current period -- eliminating the end-of-month call where every client asks for the same stock report. The billing module integrates with Xero and QuickBooks for invoice generation, reducing the process from a multi-day spreadsheet exercise to a review-and-export workflow that takes under an hour.