Consumer Durables Leader Achieves 99% Inventory Visibility with Warehouse Automation

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About the client
This consumer durables company has become a trusted brand in India, offering a wide range of innovative products in power backup, residential solar solutions, and home electricals, including inverter batteries, fans, modular switches, and LED lighting. With sprawling warehouse facilities covering 2,50,000 sq.ft., the company manages over 30,000 domestic pallets, 18,000 export pallets, and 20,000 storage locations across the country. Their daily operations involve 30+ inbound and 50+ outbound trucks, moving between 13,000 and 70,000 cases of material daily.
Challenges

Managing such a massive operation manually was proving challenging. Inefficient warehouse workflows, slow picking times, poor inventory visibility, and dependency on manual processes were slowing operations and restricting the company’s ability to scale. Without system-driven processes like FIFO, syncing inventory between SAP and their portal app delayed loading by up to 20 minutes per transaction. Pick lists of 30–40 line items could take over two hours to complete, affecting both domestic and export deliveries.

Team
Why BCI Warehouse Management System?

BCI designed a customized Warehouse Automation and Management solution leveraging Barcode technology to provide real-time visibility across all warehouse operations. The solution was fully integrated with the company’s ERP system, enabling seamless data flow and operational efficiency.

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