Manufacturing / Warehouse Operations
A manufacturing company with 4 warehouses, Noida
A barcode WMS for a Noida manufacturer with 4 warehouses. Mis-picks cut from 6% to 0.8%, and 40 hours a month of stock discrepancy hunting brought under 5.
Next.js · Node.js · PostgreSQL · Tally TDL integration · Barcode scanner support · Mobile-optimised picking UI
0.8% (was 6%)
Mis-pick rate
5 hrs (was 40 hrs)
Monthly discrepancy investigations
Eliminated
Daily manual Tally entry
The problem
Stock moving between warehouses went invisible for days. Goods marked dispatched from one site wouldn't show as received at the other until a manager picked up the phone to ask. Mis-picks were driving a 6% customer return rate, and the operations head couldn't trace the cause because nobody recorded who picked what. Every count was manual, so investigating a discrepancy meant physically recounting whole bays.
What we built
A barcode-based Warehouse Management System: goods receipt, put-away location assignment, pick-list generation with scan-verified picking, inter-warehouse transfers with live in-transit status, dispatch confirmation and daily stock reconciliation. It syncs with their existing Tally setup on a schedule, which removed three hours of manual data entry a day that had been one person's full-time job.
What it includes
Outcome
Mis-picks fell from 6% to under 0.8% in the first two months. Transfer discrepancy investigations that used to eat 40 hours a month now take under 5. The Tally sync made the manual entry role unnecessary, and that person moved on to more useful work. The operations head can see stock by location across all four warehouses on one dashboard, without calling anyone.
Common questions
Does the WMS integrate with Tally ERP?
Yes, through Tally's TDL (Tally Definition Language) interface. Stock movements in the WMS sync into Tally's inventory ledgers on a schedule, usually end of day, or in real time if your transaction volume calls for it. No double entry. We've done this for several clients on both Tally ERP 9 and TallyPrime.
Can the warehouse system work with existing barcode scanners and printers?
Yes. It handles standard 1D and 2D barcodes and works with any Bluetooth or USB scanner. Labels print on Zebra and similar thermal printers. We design the picking screens for whatever your floor team already carries, whether that's a tablet or a rugged handheld.
How long does it take to implement a warehouse management system?
For 2–5 warehouse locations with barcode picking, transfer tracking and Tally integration, expect 10–16 weeks from scope to go-live. The slowest part is usually mapping your product catalogue and location structure into the new system, so we do that alongside the build rather than after it.
What's the difference between a WMS and just using Tally for inventory?
Tally tracks stock at company level: what you own in total. A WMS tracks it at location level: which warehouse, rack and bin. Tally says you have 500 units. The WMS says 200 are in Warehouse A, Rack 3, Bin 7, 180 are on their way to Warehouse B, and 120 are on today's pick list. That detail is what gets rid of mis-picks and discrepancy hunts.
Related work
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