Client Profile
A leading textile exporter specializing in carpets and rugs, with manufacturing and warehousing operations spread across a 10-acre facility. The company managed multiple warehouse sheds within the manufacturing compound and handled a large number of SKUs created by variations in yarn colour.
Business Challenge
The client's warehouse operations had become increasingly complex. The manufacturing plant covered 10 acres and included multiple warehouse sheds. Without a WMS or clearly defined processes, the company struggled to maintain effective control over its inventory.
The complexity was further increased by the nature of the product range. Even small variations in yarn colour resulted in multiple unique SKUs, making inventory identification, storage and tracking more difficult.
The company needed to:
- Improve warehouse utilization & increase storage capacity.
- Consolidate inventory & improve inventory traceability.
- Create defined warehouse processes suitable for unskilled labor.
- Manage a large number of color-variant SKUs accurately.
- Introduce technology for real-time inventory control.
AAJ's Approach
AAJ analysed the client's sales and inventory data to understand the operational complexity and requirements of the warehouse.
Solutions implemented by AAJ:
- Customized Racking Layout: Redesigned specifically for bundled yarns, introducing pallet straps to securely hold odd-sized bundles together without tangling.
- Warehouse Design & Floor Planning: Participated in floor-strength planning and architectural layout design to maximize vertical storage capacity.
- Standard Operating Procedures: Developed lean SOPs suitable for unskilled labour and aligned with existing factory working practices.
- WMS Implementation: Integrated AAJ Pro WMS with handheld scanners for real-time data synchronization and location-wise inventory mapping.
Results
The redesigned warehouse delivered a 200% increase in storage capacity.
The additional capacity allowed the company to consolidate its inventory more effectively across the 10-acre facility.
Location-wise inventory mapping improved traceability and brought greater structure to warehouse operations.
The implementation of WMS and handheld scanners eliminated misplaced stock and enabled real-time visibility across export shipments.
Key Outcomes
| Metric | Outcome |
|---|---|
| Storage Capacity | +200% Increase |
| Inventory Layout | Consolidated Across 10 Acres |
| Inventory Traceability | Location-wise Bin Mapping |
| Technology Stack | AAJ Pro WMS Implemented |
| Inventory Tracking | Real-time Handheld Scanning |
Long-Term Business Impact
The combination of warehouse redesign, standardized processes and WMS gave the textile exporter greater control over its inventory and warehouse operations.
With consolidated inventory and synchronized data, the company gained greater agility in responding to customer requirements.
The improved operational structure also supported stronger relationships with European buyers by helping the company maintain more streamlined and reliable export operations.
