How Adani Wilmar Reduced Picking Errors by 60%+ with Softpal WMS
Adani Wilmar Ltd, one of India's largest FMCG companies (Fortune edible oil, Kohinoor rice), deployed Softpal's Warehouse Management System across 6 distribution centers to eliminate manual picking errors, achieve 99%+ inventory accuracy, and integrate real-time stock data with SAP ERP. Implementation completed in 4 weeks.
"Softpal's flexible WMS and rapid implementation have saved us hundreds of man-hours every month, delivering exceptional ROI and improved customer satisfaction."
The Challenge
Adani Wilmar operates high-volume distribution centers handling edible oils (Fortune brand), wheat flour (Kohinoor), rice, and packaged food across India. Prior to Softpal WMS, operations relied on paper-based picking sheets and manual inventory counts, which created compounding accuracy problems at scale:
- ✗Manual picking sheets causing 15–20% error rate across 6 distribution centers
- ✗No real-time inventory visibility between warehouse locations
- ✗Inability to handle seasonal peaks for edible oil, wheat flour, and rice SKUs
- ✗Lack of integration with SAP ERP for financial reconciliation
- ✗No 3D bin visualization leading to inefficient slotting decisions
The Softpal Solution
Softpal WMS was implemented across all 6 Adani Wilmar distribution centers in a phased 4-week rollout, prioritizing inbound receiving and outbound picking for highest-velocity SKUs:
- ✓Deployed Softpal WMS with RFID scanning at all inbound and outbound dock doors
- ✓Implemented real-time 3D warehouse visualization for bin assignment optimization
- ✓Integrated with SAP ERP via REST API for automated GRN creation and stock reconciliation
- ✓Configured zone-based pick routing to minimize travel distance per picker
- ✓Added cycle count scheduling with automatic variance alerts for high-velocity SKUs
Measurable Results After Softpal WMS Go-Live
Within 90 days of full deployment, Adani Wilmar's operations team reported the following improvements as measured against pre-implementation baselines across all 6 distribution centers.
Picking Accuracy: 60%+ Error Reduction
Paper-based picking sheets were replaced with RFID-guided picking routes on handheld scanners. Error rates dropped from 15–20% to under 5% across all SKUs within 30 days of go-live. High-velocity edible oil SKUs (Fortune, Vivo) achieved sub-1% mispick rates by week 8.
Travel Efficiency: 35% Less Distance Per Pick
Softpal's 3D bin visualization and zone-based routing automatically assigned fast-moving SKUs to golden zones closest to dispatch docks. Average picker travel distance reduced by 35%, directly increasing picks-per-hour and reducing labor cost per order fulfilled.
Inventory Accuracy: 99%+ via Cycle Counts
Automated cycle count scheduling replaced month-end full physical counts. Real-time variance alerts for high-value SKUs (refined oil, premium rice) triggered immediate recount workflows, achieving 99%+ perpetual inventory accuracy within 60 days.
SAP Integration: Real-Time Financial Reconciliation
Softpal WMS REST API integration with Adani Wilmar's SAP ERP eliminated overnight batch reconciliation runs. GRN creation, stock transfers, and dispatch confirmations now flow into SAP in real time, reducing month-end closing time by an estimated 2 business days.
About Softpal Warehouse Management System
Softpal WMS is an enterprise warehouse management system that provides end-to-end inventory control across the full warehouse lifecycle: inbound receiving, putaway, pick-pack-ship, cycle counting, RFID scanning, and real-time BI reporting. The system supports 3D warehouse visualization, bin-to-bin transfers, cross-docking, and integrates with SAP, Tally, Oracle NetSuite, and Zoho ERP.
Founded in 1994, Softpal has deployed WMS solutions for manufacturers, 3PLs, e-commerce fulfillment centers, and FMCG distributors across India, UAE, and Southeast Asia.
Learn About WMSRequest a DemoSoftpal WMS Core Capabilities
- ▸ RFID & barcode scanning at dock doors
- ▸ 3D warehouse visualization & bin slotting
- ▸ Zone-based pick routing & wave planning
- ▸ Cross-docking & bin-to-bin transfers
- ▸ SAP / Oracle / Tally ERP integration
- ▸ Cycle count scheduling with variance alerts
- ▸ Real-time BI dashboard & KPI reporting
- ▸ Mobile-ready for warehouse staff on handheld devices