Manufacturing / Warehouse Operations
A manufacturing company with 4 warehouses, Noida
How Nimbryx built a barcode-based WMS for a Noida manufacturer with 4 warehouses — cutting mis-pick rate from 6% to 0.8% and eliminating 40 hours/month of stock discrepancy investigations.
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 in transit between warehouses was invisible for days at a time — goods marked dispatched from one location wouldn't be acknowledged received at the other until a manager called to ask. Mis-picks were causing a 6% customer return rate that the operations head could not trace to a root cause because there was no picking record. All counts were manual, meaning discrepancy investigations required physically re-counting entire bays.
What we built
A barcode-based Warehouse Management System covering goods receipt, put-away location assignment, barcode-scan picking with pick-list generation, inter-warehouse transfer with real-time in-transit visibility, dispatch confirmation, and daily stock reconciliation. The system syncs with their existing Tally accounting setup via a scheduled integration, eliminating the three hours of daily manual data entry that had previously been the job of one full-time staff member.
What it includes
Outcome
Mis-pick rate dropped from 6% to under 0.8% within the first two months. Inter-warehouse transfer discrepancies that previously triggered 40-hour-per-month investigations dropped to under 5. The Tally sync eliminated the manual data entry role entirely, freeing that person for value-adding work. The operations head now has a live dashboard showing stock by location across all four warehouses without calling anyone.
Common questions
Does the WMS integrate with Tally ERP?
Yes. We integrate with Tally using Tally's TDL (Tally Definition Language) interface. Stock movements in the WMS sync to Tally's inventory ledgers on a scheduled basis — typically at end of day or in real-time depending on transaction volume. No double entry. We've done this integration for multiple clients running Tally ERP 9 and TallyPrime.
Can the warehouse system work with existing barcode scanners and printers?
Yes. The system supports standard 1D and 2D barcodes and works with any Bluetooth or USB barcode scanner. Label printing integrates with Zebra and similar thermal printers. We design the picking UI to work on a tablet or ruggedised handheld device — whichever your warehouse floor team already uses.
How long does it take to implement a warehouse management system?
A WMS for 2–5 warehouse locations with barcode picking, transfer tracking, and Tally integration typically takes 10–16 weeks from scope to go-live. The longest lead time is usually mapping your existing product catalogue and location structure into the new system — something we do in parallel during build.
What's the difference between a WMS and just using Tally for inventory?
Tally tracks stock at a company level — what you own in total. A WMS tracks stock at location level — which specific bin, rack, or warehouse has what. Tally tells you you have 500 units; the WMS tells you 200 are in Warehouse A, Rack 3, Bin 7, 180 are in transit to Warehouse B, and 120 are on a pick list for today's dispatch. That level of detail is what eliminates mis-picks and discrepancy investigations.
Related work
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