Warehouse Management System

End-to-end control of the material lifecycle

From vendor procurement to customer delivery — one connected system, fully traceable.

Documentsv1.0

DateApril 2025

StatusConfidential

Procurement Warehouse Production Logistics Customer

Executive Summary

Why we needs a WMS

Current State

Today's challenges

Manual and semi-manual processes across departments
Inventory inaccuracies and recurring stock discrepancies
Delayed material fulfilment stalls the production line
No single source of truth for stock visibility
Limited supply-chain traceability and audit compliance

Future State

The WMS vision

Real-time, single source of truth for all inventory
Automated request, approval and outward workflows
Complete traceability from PO to customer delivery
Material cycle time reduced by 40% or more
Full audit compliance across every transaction

>99%Inventory accuracy target

40%+Faster MR fulfilment

<30 minAutomated GRN processing

>95%On-time dispatch rate

Project Scope

Eight core modules, integrated end-to-end

Independently configurable · tightly coupled

Vendor & Procurement

Vendor onboarding, PO lifecycle, purchase approvals

Material Inward

GRN, DC verification, quality check, rejection flow

Inventory Management

Real-time stock, FIFO, SKU tracking, reorder alerts

Internal Material Requests

Dept MRs, approval workflow, outward, acknowledgement

Production Integration

Work orders, material consumption, finished goods

Logistics & Dispatch

Slot booking, transport challan, shipment tracking

Document Management

GRN, DC, PO, challan — searchable audit trail

Reports & Analytics

Dashboards, stock aging, consumption, fulfilment

End-to-End Workflow

From vendor to customer — the complete material lifecycle

Seven stages · one order reference

01 Vendor & PO creation Raise & approve the purchase order

02 Material inward / GRN Receive goods, match to PO

03 QC & inventory update Accept stock, ledger updates live

04 Material request Dept raises MR, warehouse issues

05 Production & work order Consume materials, build product

06 Finished goods store FG stocked, inventory updated

07 Logistics & dispatch Slot booked, challan, shipment

Customer delivery Order closed & audited

Documents generated Purchase Order Delivery Challan GRN Material Request Work Order Transport Challan Dispatch Confirmation

Module Deep Dive · 1 of 2

Procurement, inward & inventory

Sections A · B · C

Vendor & Procurement

Vendor master — onboarding, profiling, approval status
Purchase Order raised, routed through manager approval
Approved PO sent electronically to the vendor
Full PO lifecycle log: creation, approval chain, delivery
Captures commodity, lead time, line items and price

Material Inward & GRN

Vendor vehicle arrives — inward process triggered
Store officer raises GRN matched to the open PO
Delivery Challan recorded and verified
Quantity validated; discrepancies flagged automatically
Mandatory QC before stock is formally accepted
Rejection workflow with vendor return documentation

Inventory & Stock

Stock auto-updated the moment goods are accepted
Raw materials vs finished goods classification
Location tracking by rack, bin and lot number
Reorder-level alerts on threshold breaches
Tracks total, available, reserved qty and stock aging

Module Deep Dive · 2 of 2

Internal requests, production & logistics

Sections D · E · F · G · H

Internal Material Request workflow

Dept raises MR

→

Warehouse review

→

Approval granted

→

Material outward

→

Dept acknowledges

→

Inventory deducted

Production Integration

Customer order → Production Dept → Work Order created
Work Order triggers an MR to the warehouse for raw materials
Material consumption recorded against each Work Order
Finished goods transferred to FG warehouse on completion
FG inventory updated automatically after each run

Logistics & Dispatch

Customer or coordinator books a delivery slot
Transport Challan generated: vehicle, driver, destination
Dispatch confirmed → FG stock deducted from inventory
Inbound transport coordinated for raw-material pickup
Delivery confirmation closes the fulfilment lifecycle

GDocument Management & Audit Trail

Every GRN, DC, PO, challan, MR and acknowledgement stored under one order reference — retrievable by number, date, department or vendor. 7-year retention, GST/taxation compliant.

HReports & Analytics

Real-time dashboards: stock aging, department-wise consumption, pending MRs and order fulfilment rates, exportable to Excel and PDF.

Success Metrics

Baseline vs target — measurable outcomes

Before → After

Metric	Before		After
Inventory accuracy	~85%	→	> 99%
MR fulfilment time	2–3 days	→	< 4 hours
GRN processing time	Same-day, manual	→	< 30 minutes
Document retrieval	Hours (physical)	→	< 60 seconds
Stock-out incidents / month	Untracked	→	< 2
On-time dispatch rate	Untracked	→	> 95%

Strategic Inventory accuracy above 99% · MR cycle time cut 40%+ · full audit compliance · 200+ concurrent users · on-premise with optional cloud DR

Technical Requirements

Non-functional requirements & constraints

Build-readiness checklist

Performance

Minimum 200 concurrent users
No degradation under load
Page response under 3 seconds

Security & Access

Role-based access control (RBAC)
Department-wise visibility
Every transaction timestamped & attributed

Deployment

On-premise at AL data centres
Optional cloud hosting for DR
Web + mobile for on-floor ops

Data Retention

7-year retention for audit
GST / taxation compliance
All challans & GRNs compliant

Integration

ERP (SAP / Oracle) in Phase 2
REST API hooks prepared
Barcode hardware via AL IT

Training & Rollout

Training materials in scope
Master data onboarded pre-go-live
Dept, item & vendor codes provided

Warehouse Management System

Thank you

End-to-end digital transformation of material lifecycle operations.

ReferenceAL-WMS-2025-001

Version1.0 · April 2025

Prepared byBusiness Analysis Team

Classification: Confidential