01
Mismatched records, slow stocktake
Inventory is logged by hand and inbound/outbound are out of sync. Each stocktake means stopping work and overtime, and the causes of discrepancies are hard to trace.
RockPlus WMS
Warehouse Management System
Built on one barcode per item, it unifies receiving, put-away, kitting, outbound and stocktake in one system, so the location, status and destination of every material are clear and inventory matches records.
WAREHOUSE CONTROL CENTER
Location Utilization
BarcodeOne code per item
LocationCapacity and mixing control
FIFOHard outbound block
MSDExposure timer alerts
Material Flow · REEL 2309280016
ReceiveRegisterIQCPut-awayOutboundLine-Side
Outbound · FIFO checkEarlier batch existsBlocked
FIFO
Older batches first · violations blocked
Older batches first · violations blocked
Records Match
Ledger transactions · fully logged
Ledger transactions · fully logged
Barcode-Level InventoryTrusted quantity and status per barcode
Location Capacity ControlCapacity, mixing and fixed part-number checks
FIFO BlockingViolations stopped at outbound
Kitting VisibilityShortage status at a glance
Warehouse Challenges
Warehouse management is hard,
and not just about "recording stock numbers"
With many material types, complex batches and urgent production lines, relying on manual ledgers and experience to find materials makes it hard to keep inventory matching records, and even harder to ensure the right materials are issued.
02
Slow picking, FIFO relies on people
Where materials are and which batch is older depends on veteran staff memory, so old stock piles up and expired material is scrapped.
03
Shortages found too late
Shortages are only discovered when the work order starts, ad-hoc replenishment disrupts the rhythm, and line-side remaining quantities have no unified record.
04
Moisture-sensitive and expired materials out of control
Exposure time is calculated manually, so expired materials can still be issued to the line, creating quality risks.
UNIFIED WAREHOUSE PLATFORM
Receive, store, ship and count in one barcode system
Upward, it synchronizes ERP orders and master data; downward, it completes on-site operations through PDA, clients and label printing, so every material movement is recorded and verified.
Inbound Management
Inbound
Inbound
Inventory Management
Inventory
Inventory
Location Management
Location
Location
Kitting & Delivery
Picking
Picking
Outbound Shipping
Outbound
Outbound
Stocktake
Stocktake
Stocktake
RockPlus WMS · Warehouse Logistics Core
Barcode Inventory
Ledger Transactions
Batch Date Code
Location Info
Kitting Tasks
Stocktake Variance
PDA HandheldMaterial Receiving ClientLabel PrinterLine-Side WarehouseERP Orders & Master DataRockPlus MES
Core Capabilities
Core Capabilities
Across five stages, receive, store, ship, count and kit, it builds barcode-based warehouse control covering the full material lifecycle.
01 / INBOUND
Inbound Management
Purchase-order-driven receiving, unique barcodes generated at material registration, automatic hand-off to inspection by material attributes, and PDA scan put-away to locations.
02 / INVENTORY
Barcode-Level Inventory
Inventory is accurate to each barcode, carrying status, batch, supplier and Date Code, with ledger transactions recording every change.
03 / LOCATION
Location Management
Modeled by zone, rack and location, with capacity, mixing, fixed part-number and safety stock policies, plus location recommendations.
04 / PICKING
Kitting & Delivery
Work order activation auto-generates kitting tasks, line-side stock is allocated first, picks are recommended by FIFO, and shortage status is visible in real time.
05 / FIFO
FIFO
Based on Date Code and production date, with global and part-number switches, hard outbound blocking, and carton-level FIFO for finished goods.
06 / MSD
MSD Management
Manages opening, sealing and baking by level, accumulates exposure time, and alerts and auto-locks on expiry.
07 / STOCKTAKE
Stocktake
Three-level stocktake of task, sub-task and detail, executed on PDA and reviewed on the Web, with variances posted to the ledger automatically.
08 / OUTBOUND
Outbound Shipping
Driven by shipping plans, with pallet, carton and SN three-level packing, PDA scan shipping, and Hold interception and ledger records throughout.
Inbound & Inventory
Inbound and Inventory: every material traceable by code
From receiving to put-away, every material gets a unique barcode and enters inventory with its batch, Date Code and location, so quantities are reliable and whereabouts traceable.
01
Receiving & Barcoding
Scan-receive by purchase order. At registration a unique serial barcode is generated by rule and bound to part number, batch, supplier batch, Date Code and purchase order number, with label template printing.
Purchase OrderGoods ReceiptRegistration
02
Inspection & Put-Away
Hand off to IQC by material attributes automatically. Scan the material and location codes to put away; the system checks capacity, mixing and fixed part numbers and recommends a suitable location, modeled by zone, rack and location hierarchy.
Auto InspectionScan Put-Away
03
In-Stock & Alerts
Inventory is tracked per barcode, and status transitions and ledger transactions record every inbound, transfer, outbound and freeze. Problem materials are frozen through Hold and status, with aging, near-expiry and slow-moving alerts and inventory reports.
In-Stock ManagementRisk Alerts
Material Picking & Delivery
Kitting: materials to the line on time, and correct
Kitting no longer depends on verbal notices from planners. Once a work order is activated, kitting tasks are generated automatically and shortage status is clear at a glance.
Work Order Driven
Driven by work orders,
not by chasing people
Activating a work order generates the kitting task; line-side stock is allocated first, with raw materials warehouse as the fallback.
Kitting staff pick reel by reel on PDA following system recommendations, confirm receipt and close out, then write kitting status back to the work order. When materials are loaded onto the line, the system verifies the work order and material again, linking warehouse and production line into one data chain.
01
Work Order ActivationLinked with MES, auto-triggers kitting
02
Generate Kitting TaskTasks and part-number details generated from BOM demand
03
Line-Side Allocation FirstIf line-side stock falls short, top up from raw materials warehouse
04
FIFO Pick RecommendationLoose materials and older batches first, PDA scan reel by reel
05
Confirm Receipt and Close OutRecord issue, return and loss, and write back status
06
Line-Side Loading Error-ProofingBind station and BOM line at loading, block wrong materials
KITTING
Kit Completeness and Shortage Visibility
Kitting details record required and kitted quantities; a shortage status is the signal of an incomplete kit, found before production starts.
STENCIL
Parallel Stencil Kitting
Production supplies such as stencils follow parallel kitting tasks, linked with stencil check-in/out and usage count control.
SUPPLEMENT
Over-Issue and Replenishment
Supports over-issue replenishment tasks and line-side shortage checks, so replenishment needs have tasks and records.
LINE-SIDE
Line-Side Material Management
Loading, unloading, remaining quantity and depleted status are recorded throughout, and can be synchronized with SMT machine feeder table data.
FIFO & MSD Control
FIFO and MSD Control: risky materials cannot get out
Batch, date and exposure time are all part of the system rules. Risky materials are not merely flagged; they are blocked directly at outbound and kitting.
01 / BATCH
Full Batch Attributes
Batch number, supplier batch, Date Code, production date, arrival and expiry dates travel with the barcode.
02 / SWITCH
Two-Level Switch
FIFO verification is enabled at both global configuration and part-number master level, for flexible control by material characteristics.
03 / INTERCEPT
Hard Outbound Block
Same part numbers follow FIFO by Date Code; scan-outs that violate the rule are rejected directly by the system.
04 / PRODUCT
Carton-Level FIFO for Finished Goods
Finished goods outbound is verified against the order cartons were received into stock, shipping earlier-packed products first.
05 / MSD
End-to-End MSD Control
Manages opening, sealing, baking and accumulated exposure time by level; on expiry, a background service auto-locks material and alerts.
Rules act on operations, not on the ledger
Picking, outbound and line loading all call the same set of checks. When material shelf life is insufficient, exposure exceeds limits or batches violate rules, the system alerts and blocks on the spot, keeping risky materials from reaching the line.
FIFO ViolationSame part number with an earlier Date Code exists, ship that first
Insufficient Shelf LifeRemaining material life is under 72 hours, picking blocked
MSD Exposure ExceededRemaining MSD exposure time is under 24 hours, kitting prohibited
Location Capacity ExceededTarget location exceeds capacity or violates mixing or fixed part-number rules
Frozen MaterialMaterial is on Hold or locked and cannot be shipped or loaded
Stocktake & Outbound
Stocktake and Outbound: records match, shipments verified
Stocktake is done by barcode on PDA with variances posted to the ledger automatically; shipping is organized by carton, pallet and SN, with destinations traceable throughout.
Three-Level Stocktake
A stocktake task splits into sub-tasks by rack and location, then down to barcode details, with clear division of work and visible progress.
Variance Review and Posting
Stocktake runs on PDA and variances are reviewed on the Web; once confirmed they post to the ledger automatically, leaving a trail for every variance.
Line Unloading Stocktake
After materials are unloaded from the line, supports stocktake, scrap reporting and work order closing in coordination, and can issue unloading labels.
Barcode Label Printing
Templates and print queues are separated; server, client and PDA can all print material reel labels, pallet and carton labels, and station labels.
Outbound Shipping · Carton/Pallet-Level
Shipping PlanOutgoing InspectionPack & PalletizePDA ShippingShipping Report
Pallet, carton and SN are linked at three levels, Hold interception applies throughout shipping, and finished goods outbound also follows FIFO.
Stocktake Closed Loop · Traceable Variances
Stocktake TaskLocation Sub-TaskPDA ScanVariance ReviewLedger Posting
Every stocktake variance leaves a record, helping the warehouse locate where records and stock diverge and improve continuously.
Terminals & Integration
Terminals and System Integration
Operations are done on on-site terminals, and data stays in sync with ERP and MES, so the warehouse is no longer an information silo.
PDA
PDA Handheld Operations
Put-away, kitting picks, outbound shipping and stocktake can all be completed by scanning on PDA, with instant on-site verification.
CLIENT
Material Receiving Client
Receivers accept incoming materials by purchase order, register materials and print barcodes, creating a unique inventory record.
MES
MES Integration
Work order activation triggers kitting and material loading verifies the work order and material; warehouse and production line share one set of barcode and work order data.
ERP
ERP Data Synchronization
Synchronizes master data and documents such as customers, materials, orders and shipping plans, with interfaces managed through routing configuration.
Application
Typical Applications
Suited to manufacturers with many material types, strict batch and shelf-life requirements, and a need for close warehouse-to-line coordination.
Electronics Assembly Warehouse
Reel-level one barcode per item, tiered management of raw materials and line-side warehouses, kitting by work order and error-proofing at loading.
Shelf-Life and Moisture-Sensitive Materials
For materials sensitive to Date Code, expiry and moisture-sensitivity level, automatic timing, alerts and locking of expired stock.
High-Mix Low-Volume Kitting
When work orders switch frequently, kitting tasks and kit status are generated automatically, reducing ad-hoc replenishment and line-stop waiting.
Finished Goods Shipping and Traceability
Pallet, carton and SN three-level linked shipping, so products and shipment batches can be located quickly on customer inquiries.
FAQ
Common questions on system integration, FIFO and connectivity.
What is the relationship between RockPlus WMS and MES?
WMS manages materials through receiving, put-away, storage and outbound, while MES manages production execution. They share work order, material and barcode data: once a work order is activated, kitting tasks are generated automatically, and when materials are loaded onto the line the system verifies the work order and material, forming a continuous data chain from warehouse to production line.
How is FIFO ensured?
The system uses Date Code and production date as the FIFO baseline, with switches at both global and part-number level. Scans that violate FIFO are hard-blocked at outbound; kitting picks recommend loose materials and older batches first; finished goods outbound is verified against the order in which cartons were received into stock.
How does it integrate with ERP?
It can synchronize master data and documents from ERP, such as customers, materials, orders and shipping plans, and exchange data with external systems through configurable interface routing. The specific integration approach and write-back scope depend on an assessment of the customer's ERP open interfaces.
Does it support automated storage and retrieval systems (AS/RS) or AGV scheduling?
The current product focuses on barcode-level inventory, location management and operation control. Integration with automated warehouse equipment must be assessed separately based on equipment interfaces and project requirements.
Let every material know exactly where it is and where it should go
Built on one barcode per item, establish warehouse control with reliable inventory, FIFO and precise kitting, so warehouse and production line work in step.
