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Optimizing Warehouse Operations with Impiger’s WMS Implementation for a Leading Automobile Manufacturer

Automobile Manufacturing

Industry

7 Months

Duration

Web / Mobile

Platform

Warehouse Management System Implementation, SAP Integration, Mobile & Scanning Device Support, Inventory Optimization

Services

40% reduction in inventory handling time, 30% improvement in resource utilization, 15% reduction in inventory discrepancies

Impact Metrics

Overview of the Project

Impiger implemented a robust Warehouse Management System (WMS) for a leading automobile manufacturer, integrating seamlessly with SAP and supporting mobile scanning devices. The solution streamlined data flow across container ships, warehouses, shops, and management systems, optimized inventory movement, and ensured accurate tracking, enabling faster production and reducing manual handling.

Challenges

  1. Manual inventory handling caused delays and errors.
  2. Large-volume inventory across multiple storage locations lacked proper tracking.
  3. Case movement from warehouse to shop was inefficient.
  4. Integration with SAP for order management was complex.

Approach

  1. Developed a WMS integrated with SAP for end-to-end order management.
  2. Optimized inventory storage using FIFO principles and quick-access strategies.
  3. Automated de-stuffing, part requests, and direct part issuance to the shop floor.
  4. Integrated RFID and barcode scanning for accurate tracking.

Key Components / Integrations

WMS-SAP Integration – Seamless connection for goods receipt, part requests, and order feeding.

Inventory Optimization – Efficient storage and case movement to reduce manual handling.

FIFO Management – Ensured first-in-first-out storage for fast access and reduced stockouts.

RFID & Barcode Scanning – Real-time tracking for high accuracy in inventory management.

Mobile & Scanning Device Support – Allowed warehouse staff to manage inventory on the go.

Automated Processes – De-stuffing, part requests, and direct shop issuance reduced handling time.

Reporting & Analytics – Monitors inventory discrepancies and resource utilization.

Accelerators / IP Used

We leveraged reusable inventory tracking workflows, barcode/RFID scanning modules, and SAP integration templates. These accelerators reduced deployment time, ensured data accuracy, and improved warehouse operational efficiency.

Outcomes / Impact

  1. 40% reduction in inventory handling time through optimized workflows.
  2. 30% improvement in resource utilization across warehouse operations.
  3. 15% reduction in inventory discrepancies through real-time tracking.
  4. Faster part issuance improved production efficiency and reduced manual intervention.

Before

  1. Manual handling led to delays and errors.
  2. Inventory across multiple storage locations was hard to track.
  3. FIFO principles were not systematically applied.
  4. SAP integration and data flow were fragmented.

After

  1. Automated, SAP-integrated WMS improved accuracy and efficiency.
  2. Real-time tracking via RFID/barcode reduced discrepancies.
  3. Optimized inventory and FIFO management cut handling time.
  4. Direct issuance to shop floor accelerated production cycles.

What’s Next

Future plans include predictive inventory analytics using AI, automated replenishment alerts, enhanced mobile dashboards for real-time warehouse KPIs, and integration with IoT devices for full warehouse digitization.

Like to know more? Talk to our experts who worked on the project.

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