1. Executive Summary
A leading FMCG foodservice distributor operating on Microsoft Dynamics 365 Finance & Operations faced critical bottlenecks in floor execution. While the ERP managed inventory records, it lacked the agility to enforce FEFO compliance and real-time picking accuracy. We engineered a custom Warehouse Execution Layer that bridges the gap between ERP planning and floor action, resulting in a 35% gain in operational velocity.
2. Client Overview
A regional powerhouse in the FMCG sector serving high-stakes clients including global QSR chains, luxury hotels, and regional café networks.
- Scale: 4 Strategic Distribution Hubs
- Complexity: 2,000+ Multi-temperature SKUs
- Constraint: High sensitivity to product expiry and batch traceability.
3. Problem Statement
The "Execution Gap" manifest in three primary ways:
4. Use Case
"Enforce compliance at the point of scan." The requirement was to build a system that prevents a picker from moving to the next item unless the exact batch-expiry rules were met, ensuring 100% dispatch accuracy without sacrificing speed.
5. Solution Architecture
(Scanning & FEFO)
(Real-time Monitoring)
(Orders, Inventory, Batch Data)
6. The 6 Core Elements
7. Integrations
Standardized RESTful endpoints were used to maintain a clean decoupling from the ERP core:
- Inbound: Sales Orders & Batch Master data from Dynamics.
- Outbound: Pick-confirmations & Transaction logs back to Dynamics.
- Reporting: Flat-file sync for legacy compliance reporting.
8. Tech Stack
9. Strategic Implementation Roadmap
Our deployment follows a "Zero-Disruption" framework, ensuring the warehouse never stops moving while we upgrade the brain of the operation.
Process Mining & Gap Analysis
On-site shadowing of warehouse personnel to identify "tribal knowledge" routines that the ERP currently misses. We define the FEFO "Hard Rules" here.
Sandbox Integration (API Stress Test)
Building the RESTful bridge. We simulate peak-load sales orders to ensure the Node.js middleware handles high-concurrency without lagging the Dynamics 365 core.
The "Dark Launch" Pilot
Rollout in a single high-velocity zone (e.g., Cold Storage). System runs in parallel with existing processes to verify batch-validation accuracy.
Phased Site Rollout & Hyper-Care
Full deployment across all 4 hubs. Includes 24/7 "Hyper-Care" support and on-floor training to ensure 100% staff adoption within 48 hours.
10. Outcomes & KPIs
11. Future Enhancements
- AI Slotting: Dynamic warehouse reorganization based on velocity.
- Predictive Labor: Scaling workforce based on inbound sales forecasts.
12. Final Takeaways
Custom extensions do not "fight" the ERP; they unlock its value. By moving logic to the action point, we ensured that the ERP remains a clean ledger while the warehouse floor remains a high-speed execution machine.
