Problems we solve.

WMS Migration Readiness

Your team is preparing for a major WMS migration but lacks a structured readiness plan. Workflows are untested, operators are undertrained, and the cutover sequence has gaps.

• No formal UAT scenario library
• Training materials do not match new workflows
• Cutover sequence has unresolved dependencies
• No rollback plan defined

We build a launch readiness framework: UAT scenarios, operator training materials, cutover checklists, a risk register, and a post-launch stabilization plan.

Receiving & Putaway Breakdowns

Product is arriving correctly but inventory accuracy problems appear within hours or days. Operators work around the directed putaway process, creating confusion downstream.

• High short-pick rates after receiving
• Putaway confirmations missing or delayed
• Operators bypassing directed locations
• Staging area inventory not clearing

We map the receiving and putaway workflows, identify where operator behavior diverges from system design, and redesign the process with updated SOPs and configuration recommendations.

Pick Path Inefficiency

Pickers are spending excessive time traveling. Throughput is below target despite adequate staffing. The warehouse layout and slotting logic are contributing to travel waste.

• Low picks-per-hour vs. targets
• Pickers frequently traveling to reserve for forward stock
• Wave logic not aligned to zone layout
• High-velocity SKUs in inefficient locations

We conduct a SKU velocity analysis, review wave logic and pick path sequencing, and recommend slotting and operational changes to reduce travel and improve throughput.

Packing Defects & Validation Gaps

Outbound errors (wrong items, incorrect quantities, or missing documentation) are creating customer escalations and returns. Packing workflows lack consistent validation steps.

• Recurring wrong-item or short-ship errors
• Pack verification bypassed or skipped
• Label accuracy issues
• High customer-reported error rate

We review the end-to-end packing workflow, identify where validation steps are missing or bypassed, and design a tighter process with clear operator checkpoints.

Inventory Accuracy Issues

System counts and physical inventory do not match. Cycle counts identify discrepancies but do not resolve the root cause. Confidence in the WMS inventory is low across the team.

• Persistent location-level discrepancies
• Short picks not explained by normal variance
• Cycle count corrections not reducing error rates
• Manual reconciliation consuming team time

We investigate where discrepancy patterns originate across receiving, putaway, picking, and returns, and design workflow corrections that address root causes rather than symptoms.

Exception Aging & Poor Visibility

Exceptions accumulate in the WMS without clear ownership or resolution timelines. Management cannot see exception volume, aging, or resolution rates without manual reporting.

• Exception queues growing unmanaged
• No visibility into exception type or age
• Exceptions resolved inconsistently
• No escalation path defined

We design an exception management framework with ownership rules and resolution workflows, and build a dashboard that surfaces exception volume, aging, and trends.

Manual Reporting Processes

Supervisors and managers spend hours each day or week building operational reports in spreadsheets. Critical data is available in the WMS but not surfaced in a usable form.

• Daily shift reports built manually in Excel
• No real-time view of throughput or backlog
• Managers request data from IT for basic metrics
• Inconsistent KPI definitions across teams

We define the operational metrics that matter, map them to available data sources, and build dashboards that replace manual reporting with real-time visibility.

Launch Stabilization Support

The WMS is live, but the operation is struggling. Exception volumes are high, throughput is below target, and operators are reverting to old habits or paper-based workarounds.

• High exception rate in the first weeks post-launch
• Operators not using directed workflows correctly
• Throughput significantly below pre-launch levels
• No structured triage or stabilization plan

We provide structured stabilization support: daily exception triage, workflow corrections, operator coaching, and a short-term roadmap to reach operational stability.