Real-time inventory control and high-velocity order fulfillment for busy facilities
Engineered to reduce daily footsteps across racking aisles, prevent human picking errors, and guarantee that no outbound transport carrier leaves late due to missing manifests or unverified parcels.
Inbound ASN check-in and immediate dock discrepancy reporting
Incoming shipments are processed against electronic Advance Shipping Notices (ASNs). As trailers or ocean containers unload, operators scan each carton with a handheld PDA and assign a unique LPN license plate (GS1-128 SSCC). If a supplier delivers fewer units than invoiced, damaged cartons, or batches with expired shelf lives, the system flags the discrepancy instantly with photos and digital sign-off before goods are authorized for putaway.
Picking strategies: waves, batches, and multi-order carts
The platform organizes daily floor workloads dynamically so pickers and forklifts do not block each other in the same aisles:
- Wave Picking: Clusters open orders by carrier ramp cutoff deadlines (17:00, 18:00, 19:00) and warehouse racking zones.
- Batch Picking: Bulk gathering of identical SKUs across single-item orders for rapid downstream sorting.
- Cluster Cart Picking: Operators pick up to 24 customer orders simultaneously; the PDA screen displays the exact color-coded cart tote slot after scanning each barcode.
- S-Shape Walking Paths: Continuous one-way aisle navigation eliminating backtracking through warehouse lanes.
Packing bench with scale weight verification and direct thermal ZPL printing
Packing stations integrate directly with digital bench scales. The software verifies real package weight against the sum of expected SKU weights and carton tare. If the scale detects a discrepancy beyond the tolerance limit (e.g. 30 grams), label printing halts, preventing empty cartons or duplicate items from reaching consumers. Once validated, shipping labels stream as native ZPL directly to industrial thermal printers (Zebra, Honeywell, TSC) without browser print dialog popups.
Continuous cycle counts without shutting down warehouse operations
Keep inventory variances below 0.05% without losing a full weekend to annual physical stock takes. The system schedules automatic cycle counts by ABC turnover velocity or aisle corridors during natural operational dips, recording auditable adjustments in real time.