Common warehouse system implementation mistakes in manufacturing

Manufacturing organisations understand that one way to have a competitive edge is through supply chains.  Better inventory control, operational efficiencies and accurate order fulfilment all affect bottom line profit.  So having the right warehouse software is critical in helping have a better supply chain and how you implement it and what you put in place, are also key to getting those supply chain improvements.  So this blog discusses one of those important points, what are five common warehouse system implementation mistakes?

Not getting the process design right

The two key aspects to this are around understanding how the manufacturing warehouse processes currently work, then how they should change based on the goals and aspirations of the business.  The timing of what processes need to change, how they should change and when are critical decisions.  They will impact on both software choice and operational constraints so spend the time to get this right.

Failing to learn your data

Once your processes are designed, agreed and locked under change control you need to understand the data required to support them.  This includes information critical to run and manage your business, as well as that required to run the warehouse management system.  Your system and therefore operation will soon begin to stutter and may come to a grinding halt if you don’t pay attention to this area.

Avoiding taking a good, long, hard look at your physical operation

The warehouse management system will be modelled on your manufacturing warehouse layout including transfer areas, goods receipt and despatch docks, racking layout and configuration, floor spaces and even pillars, low ceilings and maybe some unconventional shaped floor areas.  How the warehouse system helps to manage stock flow will be based on your physical constraints and this all severely impacts how efficient your manufacturing and warehouse productivity will become.  Also during implementation do not forgot that racking, locations, zones and other areas may require labelling, hardware testing for dead spots and new workstation or other areas.

Not becoming an expert at testing

There are numerous tests that need completing when implementing a warehouse management system from testing the hardware infrastructure to ensuring the configuration matches the designed business processes.  Ensure the system is thoroughly tested in the operational environments including working with the manufacturing plant before you start final cutover plans.

No planning of your quality management system

Top warehouse management systems by their very nature are complex and therefore require serious investment in training and education.  Don’t lose this after implementation so document your processes and changes once the change control lock has been lifted.  Then consider how you will best manage on-going changes, training and education with your warehouse team.  This will help you increase labour productivity performance and keep controlling costs and inventory accuracy.