Warehouse Management System for PrestaShop
Project Overview
Developed a comprehensive, web-based Warehouse Management System (WMS) integrated as a native PrestaShop extension. The system replaces manual paper-based processes with barcode-centric workflows, optimized for handheld devices. It bridges the gap between the online storefront and physical warehouse operations, ensuring real-time inventory accuracy and high-speed fulfillment.
Core Domain Entities
- Product: Unique items tracked by SKU and variants (color/size) with dedicated Barcode/QR labels.
- Location (Slot): The smallest storage unit in a shelf, identified by a unique QR code.
- Basket: A physical batch unit used for picking. One order can be split into multiple baskets for parallel processing.
- Order: Customer purchases from PrestaShop, dynamically routed for picking based on priority rules.
Operational Modules (Handheld Optimized)
1. Picking (Outbound)
Optimized "Scan-and-Confirm" workflow where staff collect items from shelves into assigned baskets.
- Route optimization to minimize walking distance.
- Real-time progress tracking per batch.
2. Double-Check (Recount)
A secondary validation layer to eliminate human error. A different staff member scans the basket's QR and verifies all contents using a barcode reader before the order moves to packaging.
3. Packaging & Labelling
Consolidates verified baskets into shipping parcels.
- Automated generation and printing of shipping labels.
- Weight and dimension logging.
- Automatic status update to "Packed" in PrestaShop.
4. Dispatch (Carrier Handover)
Final handover to logistics providers (Post, Tipax, etc.). Staff scans the parcel QR codes to update the system status to "Handed over to Carrier," initiating customer tracking notifications.
5. Put-away (Stock Placement)
Manages incoming inventory. Staff scans a product barcode to see its designated location, then scans the shelf’s QR code to confirm placement, updating stock levels instantly.
6. Cycle Counting (Inventory Audit)
Periodic stock verification. Staff scans a location QR and audits all products within. Discrepancies are logged for supervisor review.
Technical Features & Integrations
Accounting & Sync Integration
- Automated Ledger Entry: Confirmed discrepancies from cycle counting automatically generate Inbound/Outbound vouchers in the accounting system.
- Multi-Platform Sync: Stock levels are synchronized from the accounting system to PrestaShop in real-time to prevent overselling.
Hardware-Agnostic Web Architecture
- PWA Technology: A fully responsive web interface accessible via any device with a browser.
- Scanning Support: Native support for mobile cameras and professional industrial scanners (Bluetooth/USB).
Performance & Compensation System
- Activity Logging: Real-time tracking of every action (Picking, Packing, Counting) with timestamps.
- Task-Based Rewards: Automated wage calculation based on processed volumes (e.g., number of batches picked or parcels packed).
- Manager Dashboard: Visualized KPI reports including operation speed, error rates, and zone productivity.
Strategic Management & Reporting
- Zone Management: Configuration of warehouse zones and assigning specific staff to optimized picking areas.
- Priority Scoring: Configurable rules to prioritize orders based on customer type, value, or shipping urgency.
- Issue Monitoring: A dedicated interface for managing "on-the-fly" problems, such as missing items, damaged stock, or bin discrepancies.
Project Outcomes
- 90% Reduction in Manual Errors via mandatory barcode validation.
- 65% Faster Order Processing through optimized workflows and parallel batch picking.
- 40% Labor Cost Optimization by automating data entry and performance auditing.
- Real-Time Accuracy: 100% synchronization between physical warehouse, accounting, and e-commerce.