Smart Inventory Management System – A Digital Leap in Warehouse Efficiency

🧩 Challenges

Hindalco Industries faced significant inefficiencies due to a manual inventory management process. Key operational issues included: 🔧 Operational & Data Challenges • Frequent manual data entry errors during GRN, issue, return, and physical stock updates. • Slow transaction cycles due to reliance on paperwork for receiving, storage, and issue. • No real-time inventory visibility across warehouse processes. • Tedious and mismatch-prone physical verifications during audits. 📦 Inventory Management Issues • ERP stock mismatch due to delayed or skipped entries. • Risk of overstocking or stockouts from lack of alerts and live data. • Inability to enforce FIFO/FEFO for expiry-prone items. • Inefficient returns tracking for rejected or damaged goods. 🔄 Integration & Traceability Gaps • Disconnect between physical operations and ERP updates. • Low traceability — no audit trail of material movements. • Lack of serial/unique identification for similar-looking items. 📊 Reporting & Compliance Risks • Delayed/inaccurate reporting due to manual ERP updates. • High risk during audits and tracebacks without proper data capture. 👷‍♂️ Manpower Dependency • Heavy reliance on experienced staff for accuracy. • Time-consuming training for new employees without digital tools.

✅ Customer Requirements

• Barcode-based tracking from gate entry to GRN, even when multiple invoices are involved. • Auto-population and validation of GRNs in barcode system linked to Oracle EBS. • Barcode support for miscellaneous items, project inventory, and returned/rejected stock. • Access control at OU and organization level. • Real-time integration of barcode transactions with Oracle EBS for full synchronization.

⚙️ Solution Overview

Key features: • Auto-GRN creation directly from gate entries and invoices. • Real-time data capture and validation of quantities before barcode generation. • Live inventory status across stages: receiving, storage, issuing, and returns. • HHT-based mobile operations (via Wi-Fi) for on-ground staff to manage stock movements, stock-taking, and returns. • User-level access controls, and complete ERP synchronization for seamless operations.

🌟 Conclusion