One of the largest FMCG manufacturers in Indonesia, with a diverse portfolio spanning personal care, pet care, home care, and food & beverage, needed to streamline and digitize its warehouse operations across four factory locations.

The operational landscape included Raw Material (RM), Packaging Material (PM), and Finished Goods (FG) warehouses, all of which had to be integrated into the company’s existing ERP system.

1. The Challenge

The key operational challenges were distinct across warehouse types:

• In the Raw Material warehouse, weighing and validation processes were critical. Materials needed to be weighed precisely before being released to production lines, with full traceability and zero tolerance for variance.

• In the Packaging Material warehouse, the challenge was operational efficiency: even when only a partial quantity of packaging material was required for production, the entire pallet had to be delivered to the line. This required a system smart enough to track partial usage, manage returns, and maintain inventory accuracy.

• In the Finished Goods warehouse, high outbound shipment volumes meant the order fulfillment process had to be fast, accurate, and synchronized with transport scheduling.

Managing these complexities across four separate manufacturing sites—each with its own physical layout, material flow, and production demand—required a scalable and flexible warehouse management solution.

2. Our Solution

Largo WMS was deployed across all four factory locations to unify and optimize RM, PM, and FG warehouse operations. The system was tightly integrated with the client’s ERP, providing real-time synchronization for inventory movements, material staging, and production support.

Key solutions tailored to each challenge included:

• Weighing process control in RM warehouses: Largo WMS enforced precise material dispensing through integrated weighing stations, ensuring that the actual quantity issued matched production requirements and was fully traceable to specific batches.

• Full pallet tracking with partial usage logic in PM warehouses: Largo WMS was configured to deliver full pallets to production while still managing the partial consumption of packaging materials.

• Optimized outbound workflows in FG warehouses: We implemented wave picking, dynamic staging, and dock scheduling to ensure large volumes of orders were processed and loaded efficiently for nationwide distribution.

This unified approach allowed the client to manage diverse material types and operational flows using a single system, without compromising control or performance.

3. The Outcome

The rollout of Largo WMS across the four factories resulted in substantial operational gains:

• Seamless ERP integration, enabling synchronized material and order data across supply chain functions.

• Improved weighing accuracy and material issuance in RM warehouses, reducing production interruptions and waste.

• Efficient PM handling, with better visibility of partial pallet usage and return flows—minimizing material loss and manual reconciliation.

• Faster outbound throughput in FG warehouses, supporting high-volume shipment schedules and tighter delivery SLAs.

By standardizing warehouse operations across locations and material types, the client achieved greater consistency, operational agility, and end-to-end visibility. Largo WMS remains a critical backbone in their factory network’s digital operations.

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