Program Overview
This immersive program empowers warehouse, IT, and supply chain professionals to understand, evaluate, and implement Warehouse Management Systems (WMS) along with Barcode and RFID-based tracking. The course covers core WMS functionalities—such as inbound/outbound processing, inventory control, picking/putaway optimization, and integration with ERP systems. It also dives into Barcode/RFID technologies, covering tag selection, scanning infrastructure, real-time visibility, and serialization. Through live system walkthroughs and real-world case studies, participants learn how to enhance warehouse productivity, reduce manual errors, and enable traceability in complex supply chains.
Features
- Understand the architecture and modules of a WMS and evaluate vendor options
- Plan WMS implementation with focus on data migration, training, and change management
- Apply Barcode/RFID technology for inventory tracking and real-time visibility
- Optimize warehouse throughput and accuracy using digital execution tools
Target audiences
- Warehouse Managers
- Process Improvement Leads
- Inventory Controllers
- Project Managers
- SCM IT Teams
Curriculum
- 6 Sections
- 47 Lessons
- 1 Day
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- WMS – Role, Benefits & Implementation Journey8
- 1.1Concepts: What WMS does – location control, task management, system-directed put-away, traceability
- 1.2WMS vs ERP vs WCS, Real-time Updates, Scan-and-Confirm, Bin-level Visibility
- 1.3Inventory accuracy
- 1.4Picking speed
- 1.5Cycle count automation
- 1.6Paperless transactions
- 1.7Real-life Case: Automotive spare parts firm improved inventory accuracy from 85% to 99.2% post-WMS rollout
- 1.8WMS readiness checklist (process maturity, master data, integration)
- WMS Features & Configuration Elements8
- 2.1Receiving, Put-away, Slotting
- 2.2Order Picking, Packing, Shipping
- 2.3Cycle Counting, Returns Handling
- 2.4ASN, Pick-by-Line vs Pick-by-Order, Put-Away Strategy, Backflush
- 2.5Picking rules
- 2.6Zone logic
- 2.7FIFO/LIFO methods
- 2.8Exercise: Configure a WMS mock-flow for 4 common warehouse scenarios (FG, raw material, e-com, spare parts)
- Barcode & RFID – Tech, Formats & Scanning Logic7
- 3.11D vs 2D codes (EAN-13, QR, Code 128)
- 3.2Labeling logic (SKU, location, pallet, shipment)
- 3.3Passive vs Active
- 3.4Frequency types (LF, HF, UHF), tag types, reader range
- 3.5GS1 Standards, Scan Failures, Read Accuracy %, EPCIS
- 3.6Electronics distributor reduced loading errors by 70% with scan-based staging
- 3.7Barcode/RFID label design sheet (SKU code + location + batch + expiry encoding)
- Integration with Operations & Devices7
- 4.1Hardware Integration: Scanners, Mobile Terminals, RF Guns, RFID Gates
- 4.2ERP (SAP, Oracle)
- 4.3TMS, ASN, EDI interfaces
- 4.4API Mapping, Scan-to-System, Real-time Sync
- 4.5Stock mismatch due to dual entry (manual + scan)
- 4.6Case Study: FMCG company migrated to handheld-driven workflows to eliminate lag in put-away
- 4.7Exercise: Map one warehouse process end-to-end (e.g., picking) from scanner-to-system
- WMS Implementation – Pitfalls, Governance & Go-Live Strategy9
- 5.1Poor master data
- 5.2Resistance from warehouse staff
- 5.3Underestimated training effort
- 5.4UAT (User Acceptance Testing), Pilot Rollout, Legacy System Handoff
- 5.5Master cleanup → parallel run → physical inventory baseline → phased adoption
- 5.6Steel processor failed initial WMS go-live due to improper zone coding
- 5.7WMS Go-Live Tracker
- 5.8User Training Log
- 5.9Change Control Matrix
- Performance Monitoring & ROI Tracking8
- 6.1Inventory Accuracy %
- 6.2Pick Accuracy %
- 6.3Scan Compliance Rate
- 6.4Cycle Count Effectiveness
- 6.5Dock-to-Stock Time
- 6.6WMS Audit, System Uptime, RF Device Usage %, Data Latency
- 6.7Medical distributor used WMS dashboards to reduce stockout alerts by 85%
- 6.8Activity: Build a WMS health check template (daily/weekly metrics)
Instructor
