A globally recognized In-Vitro Diagnostics manufacturer with a strong footprint across domestic and international markets operates a state-of-the-art facility on the outskirts of Cochin. Established with a mission centered on the welfare of mankind, the organization has grown into one of the fastest-expanding IVD companies, supported by a vast distributor network and a significant presence in the global OEM segment.
As volumes of raw materials and finished goods increased, the need for a structured warehouse execution platform became critical. The objective was to create a digitally controlled environment that could manage expiry-driven inventory, enable barcode-based traceability, accelerate quality-controlled material flow and support complex distribution workflows while staying fully aligned with ERP-driven operations.
The warehouse required a system-driven location hierarchy with dedicated zones for raw materials and finished goods, governed by FIFO and FEFO logic, which is essential for handling expiry-sensitive IVD materials. Manual processes and non-standard storage practices limited space utilization and slowed material movement.
At the inbound stage, the absence of a barcode-based labelling mechanism meant dependency on manual data entry, which increased the risk of errors and restricted end-to-end traceability. The quality control process also needed faster and fully traceable raw material issuance, along with controlled transfer of QC-cleared stock to production using audit-ready digital documentation.
Finished goods operations demanded custom picking and packing workflows with the ability to capture unique barcodes for every unit and synchronize them with the ERP for distributor reward programs and scheme tracking. In dispatch, the team required automated courier manifestation to ensure shipment accuracy and correct vehicle loading without manual reconciliation.
The rollout followed a phased execution strategy to maintain operational continuity while introducing new process controls.
Phase 1 – Raw Material and Packing Material Flow Implementation
The core WMS environment was deployed to digitize inbound, storage, QC issuance and production supply processes. Barcode labels were generated at the GRN stage, enabling system-driven bin allocation and complete traceability of material movement across temperature-controlled and standard storage zones.
Phase 2 – Finished Goods Flow Implementation
Finished goods workflows were configured with customized picking and packing logic. Unique barcodes were captured for each unit and shipment-wise packing lists were generated automatically to eliminate dispatch mismatches and improve loading accuracy.
A structured user access model supported operational and administrative control:
The implementation also included:
The WMS implementation successfully streamlined location management for both raw materials and finished goods, significantly improving overall warehouse space utilization. The system also provided management with clear visibility into user productivity while improving dispatch turnaround time and operational efficiency.
