Excel: Warehouse Management System

Overview:

In a high-volume warehouse storing perishable goods, pallets were stacked three high and ten deep. The warehouse used a system to track the location, product, and expiry date of each pallet. Daily, staff needed to consolidate stock by use-by date to make room for bulk incoming deliveries, often up to 30 pallets at a time.

We discovered the inventory control system could export data as a CSV file. We developed an Excel application that analyzes this data and provides actionable insights:

  • Action Points:

    • Identifies where to move stock from and to.
    • Orders stock movement by earliest use-by date.
    • Prepares staff for full row spacing to accommodate next-day deliveries.
    • Flags any pallets in incorrect locations.
    • Prints outgoing goods stickers to identify order and pallet count.

  • Visual Overview:

    • Provides a graphical representation of the warehouse.
    • Color-coded rows indicate the status of locations, fullness, and stock priority.

Problems:

  • Manual stock consolidation was time-consuming.
  • Incorrect ordering by use-by dates required reorganization.
  • Incorrectly placed stock led to inefficiencies.
  • Reactive stock consolidation caused bottlenecks, delaying the storage of incoming goods and loading of outgoing goods.

Solutions:

  • Automated Stock Consolidation: The Excel-based WMS determined optimal stock movement and consolidation based on use-by dates and stock codes.
  • Error Identification: The system flagged incorrectly placed stock.
  • Proactive Organization: Staff could consolidate stock at the end of the day, ensuring:
    • Inward goods staff had a list of available locations for the next day.
    • Simplified operation: Staff easily extracted data, imported the CSV file into the Excel WMS, and processed the report with a single click.

Impact:

  • Efficiency: Reduced time spent manually organizing stock.
  • Accuracy: Improved ordering by use-by dates, preventing the need for reorganization.
  • Proactivity: Prepared staff for incoming deliveries, reducing bottlenecks.
  • Ease of Use: Simple data extraction and report generation process.

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