OVERVIEW
A mid-sized medical warehouse was struggling with outdated, manual processes. Inventory was managed through memory and spreadsheets, with no formal system in place to track expiration dates, product locations, or returns. This lack of structure led to frequent errors, wasted products, and compliance risks, which are critical in the medical industry where traceability and regulatory adherence are essential.
EpicRise stepped in to transform the facility, introducing barcode scanning, mobile printing, and a cloud-based Warehouse Management System (WMS). Organizing using a proper zoning system and accurate labeling resulted in a dramatic improvement in accuracy, efficiency, and compliance.
BACKGROUND
The warehouse operated without a WMS, relying on a single employee’s memory and scattered spreadsheets to manage inventory. Products were placed randomly, expiration dates weren’t tracked, and there was no standardized process for receiving, put-away, or internal circulation. This created a fragile system prone to errors and regulatory violations.
Receiving was entirely manual, with no barcode scanning or structured checks for overages or damages. Put-away decisions were based on experience rather than system logic, and the lack of signage or location coding made training new staff difficult. Bulk transfers were undocumented and handled manually, while inventory counts were inconsistent and unreliable.
EPICRISE’S APPROACH
EpicRise conducted a full operational audit and developed a roadmap to digitize and standardize the warehouse. Their strategy focused on three core areas: systems, space, and technology.
EpicRise implemented a cloud-based WMS with barcode functionality, enabling digital tracking of every product from receiving to dispatch. Waybills and circulation records were digitized, and cycle counts were introduced to monitor discrepancies and improve accuracy.
The warehouse layout was restructured with vertical racks and clearly defined zones for receiving, staging, returns, and bulk transfers. Durable barcode labels and location identifiers were installed to guide staff and streamline operations.
Industrial thermal printers (Zebra ZD421) were deployed for scalable barcode labeling. Staff were equipped with Honeywell Xenon 1952G-SR scanners and mobile devices to enable real-time scanning and full traceability across all warehouse functions
SOLUTIONS DELIVERED
- Printers: Zebra ZD421
- Scanners: Honeywell Xenon 1952G-SR
- WMS Implementation:
- Real-time inventory visibility
- Structured put-away and internal circulation tracking
- FIFO/FEFO enforcement
- Full traceability with digital logs
- Created standardized SOPs and provided onsite worker training
RESULTS
The transformation delivered measurable improvements across the board. Inventory accuracy rose from approximately 70% to 96% within three months. Space utilization increased by 25%, maximizing existing capacity. Expiry-related waste dropped by 40%, saving approximately $5,000 annually. Cycle count variance was reduced by 55%, improving audit reliability. Staff onboarding time decreased by 40% thanks to standardized workflows. Internal circulation time was cut by 30%, streamlining bulk transfers.
Customer Testimonial
“We used to run on spreadsheets and memory, products expired, audits were stressful, and mistakes piled up. EpicRise set us up with scanning, labels, and a proper WMS. Now we’re accurate, compliant, and confident.”
CONCLUSION
The transformation delivered measurable improvements across the board. Inventory accuracy rose from approximately 70% to 96% within three months. Space utilization increased by 25%, maximizing existing capacity. Expiry-related waste dropped by 40%, saving approximately $5,000 annually. Cycle count variance was reduced by 55%, improving audit reliability. Staff onboarding time decreased by 40% thanks to standardized workflows. Internal circulation time was cut by 30%, streamlining bulk transfers.
