Automotive ERP:
Warehouse Management OS.
Architected a high-throughput Warehouse Management System (WMS) tailored for automotive parts distribution networks. Bridged rigid legacy mainframe terminals with modern, touch-optimized interfaces to automate inventory allocation, container tracking, and First-In, First-Out (FIFO) dispatches.
Eradicating Blindspots in High-Velocity Auto Parts Yards
In the automotive aftermarket, receivers and parts dealership managers were unable to view the specific contents of incoming freight containers before they arrived at the dock. This created severe staging bottlenecks, stock disorganization, and accounting ledger discrepancies.
Additionally, QA inspections repeatedly ground fulfillment lines to a halt. The objective was to design a comprehensive system providing complete parts traceability from inbound container arrival to technician dispatch.
End-to-End Main Warehouse Fulfillment Journey
The Core WMS Operational Engine
Automating reception, storage allocation, bin navigation, picking routing, and demand planning.
Dynamic Order Routing
Automatically allocates inventory in real time and calculates optimized shortest-path walking routes for warehouse pickers.
RFID & Scanner Telemetry
Integrated real-time RFID tracking and barcode scanning, alerting floor operators to stock misplacements instantaneously.
In-Line Quality Assurance
Automated defect inspection alerts during receiving, routing damaged components to return queues without stalling healthy pallets.
Automated Dispatch & FIFO
Enforces First-In First-Out inventory dispatch, automatically generating carrier documentation and hazardous materials manifests.
Continuous Cycle Counting
Scheduled micro-counts reconcile inventory discrepancies without shutting down active warehouse zones.
AS400 Mainframe Bridge
Constructed a modern UX layer that synchronized seamlessly with legacy AS400 green-screen databases, avoiding millions in migration debt.
On-the-Floor Field Shadowing
Conducted on-site ethnographic shadowing in active US & EU logistics hubs to uncover real-world workarounds and ergonomics under high physical stress.
Requirement Analysis & Parts Categorization
Mapping space allocation, bin capacities, and technician requisition habits.
Supply Chain Information Architecture
Multi-tier taxonomy covering parts settings, dealership inventory, and RO sales.
11-Step Task Simplification Framework
The Deployed Floor Experience
Role-Based Floor Operator View (High Contrast)
Detailed Part Metadata & Dispatch Ledger
Measured Financial Outcomes
Scan Error Drop
High-contrast feedback loops and audio cues reduced misplaced parts and double scans.
Backend Mainframe Disruption
The modular frontend preserved underlying AS400 core business logic, avoiding millions in system migrations.
Receiving Throughput
Advance container visibility eliminated dock queuing, speeding parts from container to shelf in record time.
Explore All Case Studies & Methodology
Review the executive summary, resume, and contact Rupak Biswas
