Warehouse Management for Building Materials
WMS with barcode scanning, pick/pack workflows, real-time stock levels and delivery scheduling. Replaced paper-based warehouse operations and reduced picking errors.
Building materials wholesaler and distributor
A WA building materials company distributing 4,000+ SKUs — timber, hardware, plumbing, electrical and finishing products to builders, contractors and retail customers. They operated a 5,000sqm warehouse with 18 staff.
Warehouse operations ran on paper. Pick lists were printed from the ERP, walked around the warehouse, marked up by hand and returned to the office for data entry. Stock levels were updated at end of day. Returns and adjustments were processed in batches weekly.
What needed to change
Picking errors were expensive. Paper pick lists led to wrong-item and wrong-quantity errors at a rate of 8%. Each error created a return cycle — customer call, return logistics, credit note, restock, re-pick and re-deliver. The company estimated $15,000/month in error-related costs.
Stock levels were never accurate. End-of-day updates meant the system was always behind. Sales reps quoted stock availability that did not match what was actually in the warehouse. Builders who needed materials that day drove across town to find the item was out of stock.
Delivery scheduling was manual. Orders were allocated to delivery runs by the dispatch supervisor using a paper schedule. Route planning was based on experience, not optimisation. Trucks sometimes left half-empty or made unnecessary backtracking.
What we built
A warehouse management system with barcode scanning, guided picking, putaway logic, real-time stock visibility, and delivery scheduling — integrated with the existing ERP.
Guided Picking
Barcode scanner-guided picking with optimised walk paths. Pick list sequenced by warehouse location. Each pick confirmed by scanning the item barcode — wrong item rejected immediately.
Receiving & Putaway
Inbound goods scanned at receiving. System directs putaway to the optimal location based on product category, pick frequency and available space. Stock levels update in real time.
Stock Management
Real-time stock levels across all 4,000+ SKUs. Cycle counting replaces annual stocktakes. Automatic reorder triggers based on min/max levels and sales velocity.
Delivery Scheduling
Orders grouped into delivery runs based on location and vehicle capacity. Route optimisation minimises distance and backtracking. Driver app with delivery sequence and proof of delivery.
How it works
Order received from ERP
Customer order flows from the ERP into the WMS. System checks stock availability and creates a pick task assigned to the next available picker.
Picker follows guided path
Picker's handheld device shows the optimised pick sequence. Scanner guides to each location. Item barcode scanned to confirm correct product and quantity.
Order packed and staged
Picked items brought to packing station. Order checked against pick list. Packed and labelled for delivery or customer collection.
Delivery run planned
Dispatch allocates orders to delivery runs. Route optimised by location. Driver receives the run sheet on the mobile app with navigation.
Delivered with proof
Driver follows the optimised route. Customer signs on the device for proof of delivery. Delivery status updates in real time for the dispatch team.
Measurable outcomes
Picking errors cost us $15,000 a month. Since going live with barcode scanning and guided picking, we have virtually eliminated wrong items and wrong quantities. The builders trust that what we promise is actually in stock.
How we delivered it
Warehouse Analysis
2 weeksMapped the warehouse layout, product locations, pick paths and delivery routes. Analysed pick error data for root causes. Observed receiving, putaway, picking and dispatch workflows across a full week.
WMS Build
5 weeksBuilt the WMS with guided picking, barcode scanning, putaway logic, stock management and cycle counting. Integrated with the existing ERP for order flow and stock sync.
Delivery & Mobile
2 weeksBuilt the delivery scheduling module with route optimisation. Developed the driver mobile app with run sheets, navigation and proof of delivery capture.
Rollout
1 weekDeployed hardware — handheld scanners, label printers and mobile devices. Trained warehouse staff on guided picking and receiving workflows. Ran parallel with paper for 1 week to validate.
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