Inventory Management

Automated Inventory Capture from Procurement to Dispatch

The Problem

Manual inventory tracking is slow, error-prone, and leads to cascading operational problems:

  • Inventory inaccuracy causes stock-outs and overstocking
  • Manual counting takes hours and disrupts operations
  • Expiry and wastage due to poor FIFO enforcement
  • ERP discrepancies because data entry happens hours or days later
  • No traceability for recalls or quality issues

As we say: "ERPs Repeat The Lies We Tell Them". Manual data entry ensures your system never reflects reality.

The IoTReady Solution

Capture inventory data automatically at every step—from inbound to storage to dispatch

Automated Cycle Counting

RFID-based bulk reading or barcode scanning completes cycle counts in minutes instead of hours.

Weight Validation

Auto-capture weight data at procurement and dispatch to detect discrepancies and prevent fraud.

Real-Time ERP Sync

Inventory updates flow directly to SAP, Zoho, ERPNext, or custom ERP systems—no manual entry.

FIFO Enforcement

Track batch expiry dates and ensure first-in, first-out automatically. Reduce wastage and spoilage.

End-to-End Traceability

Track every item from receiving to dispatch. Complete audit trail for compliance and recalls.

Exception Alerts

Instant notifications for missing inventory, unauthorized movements, or discrepancies.

Technology Stack

We use the right mix of technologies for your inventory types and workflows

Barcode Scanning

Best for: SKU-level tracking with existing labels

WiFi-enabled handheld scanners and mobile apps capture barcodes at inbound, storage, picking, and dispatch.

Use cases: Retail, e-commerce, SKU identification

RFID (UHF/HF)

Best for: Bulk inventory counting and validation

Read hundreds of items simultaneously without line-of-sight. Complete cycle counts in minutes.

Use cases: Apparel, containers, pharmaceutical batches

Weight Scales

Best for: Quantity validation at procurement and dispatch

Auto-capture weight data and sync with ERP. Detect discrepancies and prevent fraud.

Use cases: Agriculture, metals, raw materials

QR Codes

Best for: Low-cost item identification with smartphones

Print QR codes on labels. Operators scan with mobile app for instant check-in/check-out.

Use cases: Small operations, batch tracking, equipment logs

Real-World Results

BigBasket

Procurement & Inventory

11 integrated workflows across 40 sourcing centers, 30 fulfillment centers, 600+ dark stores. Inventory and asset traceability, automated labeling, delivery tracking. Inventory accuracy improved from 85% to 99%.

Read full story →

Vedanta

Raw Material to Finished Goods

End-to-end traceability from copper/aluminum ingots to finished products. Reduced inventory discrepancies by 40%.

Read full story →

Zomato

Fresh Produce Procurement

Real-time tracking of fruits and vegetables from farm to fulfillment center. Automated quality checks and instant farmer payouts reduce wastage.

Typical Workflow

1. Inbound Receipt

Scan barcodes or read RFID tags as goods arrive. Capture weight and quality checks. Auto-update ERP with GRN.

2. Storage & Putaway

Track bin locations and quantities. Ensure FIFO compliance based on expiry dates and manufacturing dates.

3. Picking & Packing

Validate picked items against order. Prevent wrong-item errors with instant operator feedback (green/red light).

4. Dispatch

Final weight validation before dispatch. Complete traceability from procurement to customer delivery.

5. Cycle Counting

Automated daily or weekly cycle counts. Identify discrepancies immediately and investigate root causes.

Business Impact

99%

Inventory Accuracy

From typical 85-90% with manual tracking

80%

Faster Cycle Counts

From hours/days to minutes

30-50%

Wastage Reduction

Through FIFO enforcement and expiry tracking

Real-Time

ERP Updates

No manual data entry delays

Frequently Asked Questions

How long does it take to deploy inventory management automation? ▼
Typically 1-3 weeks for initial deployment. We start with a pilot in one warehouse or zone (3-7 days to go live), validate the accuracy improvements, then roll out to additional locations using the proven configuration. Most customers are operational across multiple facilities within 4-6 weeks.
Does this work with our existing barcode scanners and scales? ▼
Yes. Our platform auto-detects most WiFi-enabled handheld scanners and industrial weight scales. We support all major brands (Zebra, Honeywell, Essae, Clonet) via standard protocols. Use your existing hardware or we can provide new devices—no vendor lock-in.
How does ERP integration work? ▼
We integrate with SAP, Zoho, ERPNext, Tally, and custom ERPs via REST APIs or database connectors. Inventory movements (GRN, putaway, picking, dispatch) sync automatically in real-time. See our ERP integration pages for technical details and supported systems.
Can we use RFID for faster cycle counts? ▼
Absolutely. RFID enables bulk scanning—read hundreds of items simultaneously without line-of-sight. Complete cycle counts in minutes instead of hours. We support UHF RFID for containers, pallets, and high-volume SKUs. Barcode scanning remains available for individual item tracking.
What's the typical ROI for inventory automation? ▼
Most customers see inventory accuracy improve from 85-90% to 99% within the first month. Cycle count time reduces by 80% (from hours to minutes). Wastage drops 30-50% through automated FIFO enforcement and expiry tracking. ROI typically realized within 3-6 months through reduced stock-outs, lower wastage, and faster cycle counts.
How does FIFO/FEFO enforcement work? ▼
System tracks batch numbers, manufacturing dates, and expiry dates for every item. We support both FIFO (First In First Out) and FEFO (First Expired First Out) based on your needs. During picking, operators are guided to pick the right stock automatically—oldest manufactured (FIFO) or nearest to expiry (FEFO). If they scan a newer batch when older stock is available, the system gives a red light and blocks the transaction. This prevents expiry wastage and ensures compliance with quality standards.
Can we customize workflows ourselves? ▼
Yes. Our low-code platform allows your team to modify workflows with ~20 lines of Python. Configure receiving rules, quality checks, FIFO logic, and exception handling without waiting for developers. Changes deploy in minutes, not weeks.
Do we need to change our existing workflows? ▼
Minimal to no changes required. We augment your existing workflows, not replace them. Operators continue their normal receiving, putaway, picking, and dispatch processes—we add automated data capture and validation. The system adapts to how you work today, eliminating manual data entry without forcing new SOPs. You keep your processes, we make them traceable and error-free.
What if we don't have WiFi in the warehouse? ▼
Our mobile apps work offline—operators can scan and capture data without connectivity. Data syncs automatically when WiFi becomes available. For permanent installations, we can provide 4G cellular gateways with M2M SIM cards (Airtel, Jio, Vodafone).
How scalable is the platform? ▼
Built for scale from day one. Handles 1000s of requests per second and millions of transactions daily. Currently deployed at 1500+ warehouses. BigBasket example: 99% inventory accuracy across 670+ locations (40 sourcing centers, 30 fulfillment centers, 600+ dark stores). Multi-location dashboards come standard.
What about data security and compliance? ▼
We support on-premise deployments for sensitive environments, encryption at rest and in transit, role-based access controls, and complete audit trails for all inventory movements. Compliant with ISO standards for data security. Complete traceability for regulatory audits (FSSAI, FDA, etc.).

Ready to Automate Your Inventory?

Eliminate manual counting and improve inventory accuracy with real-time visibility and automation

Schedule a Demo Explore Other Solutions