Warehouse Inventory Tracking Software Transformation
Cut labor costs by over 1/3 and doubled productivity with custom inventory intelligence.
About the client
Regional Distribution & Logistics Company
United Kingdom
A mid-sized regional distribution company operating 4 warehouse facilities across the UK, managing over 80,000 SKUs for retail and pharmaceutical clients. Known for their reliability and compliance focus, they were struggling to scale operations without proportionally scaling headcount.
Technologies used
Results at a glance
95%
Inventory accuracy
75%
Reduction in manual errors
35%+
Labor cost reduction
2Γ
Productivity increase
Within six months of go-live, the client had re-deployed three FTEs from cycle counting to value-added roles, reclaimed two major retail accounts that had been at risk, and passed their first unannounced pharmaceutical compliance audit without a single finding.
Overview
The context
Modern warehouse operations demand real-time visibility, precise stock counts, and intelligent workflows β yet most mid-market operators still rely on spreadsheets and outdated WMS solutions that can't keep up with the pace of commerce.
We partnered with this logistics operator to build a purpose-fit warehouse intelligence platform: one that talks directly to their RFID infrastructure, IoT temperature sensors, and existing ERP, giving every worker a real-time, accurate picture of stock β and giving management a live operations dashboard that eliminates end-of-day surprises.
The challenge
The Challenge
Inaccurate stock counts were causing pick errors that averaged 12% per shift β translating to returns, client chargebacks, and reputational damage with key retail accounts. Manual cycle counting took three dedicated staff members off the floor for two full days each week.
Temperature-sensitive pharmaceutical inventory had no automated monitoring: staff were manually logging sensor readings on paper and filing compliance reports by hand. One missed reading could mean a costly batch rejection.
Our solution
What We Built
We built a custom WMS layer on top of their existing ERP, with native RFID reader integrations, real-time IoT sensor ingestion, and a mobile-first interface for floor staff. The system performs continuous cycle counting via RFID sweeps β eliminating the dedicated counting shifts entirely.
A supervisor dashboard surfaces live pick accuracy, stock velocity, temperature excursions, and shift productivity, with configurable alerting for any threshold breach.
- RFID-based continuous cycle counting β zero manual counts
- IoT temperature sensor integration with automated compliance logging
- Mobile-first React Native app for floor staff
- ERP bi-directional sync (SAP Business One)
- Live supervisor dashboard with pick accuracy tracking
- Automated HACCP compliance reporting
Outcomes
The results
Within six months of go-live, the client had re-deployed three FTEs from cycle counting to value-added roles, reclaimed two major retail accounts that had been at risk, and passed their first unannounced pharmaceutical compliance audit without a single finding.
95%
Inventory accuracy
75%
Reduction in manual errors
35%+
Labor cost reduction
2Γ
Productivity increase
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