Warehouse Management System for PrestaShop

Project Overview

Developed a comprehensive warehouse management system (WMS) as a modular PrestaShop extension featuring optimized handheld device interfaces and barcode scanning capabilities. The system automates order processing, inventory management, and fulfillment workflows while providing intuitive mobile interfaces for warehouse staff.

System Architecture

Modular PrestaShop Integration

• Native PrestaShop module with custom database tables
• Hook system integration with PrestaShop order events
• Admin interface within PrestaShop backend
• Real-time synchronization between web and mobile interfaces

Optimized Handheld Interfaces

Role-Specific Mobile Applications

1. Order Picking Staff Interface

Dashboard → Assigned Batches → Barcode Scan → Quantity Entry → Confirmation

• Simple scan-and-confirm workflow
• Visual batch completion progress
• Error prevention with validation rules
• Offline capability with sync
• Route optimization display

2. Quality Control/Recount Staff Interface

Batch Selection → Barcode Scan → Quantity Verification → Discrepancy Logging → Final Approval

• Mandatory barcode scanning for verification
• Discrepancy categorization and reporting
• Photo capture for evidence (optional)
• Supervisor approval workflows
• Real-time error flagging

3. Packaging Staff Interface

Ready Batches → Package Scanning → Label Printing → Carrier Selection → Shipping Confirmation

• Package barcode generation and scanning
• Shipping label printing integration
• Carrier service selection
• Weight and dimension entry
• Final status update

4. Stock Placement Staff Interface

Incoming Products → Location Barcode Scan → Product Barcode Scan → Quantity Entry → Placement Confirmation

• Location scanning for putaway
• Product-to-location matching
• Stock level updates in real-time
• Location optimization suggestions
• Error prevention for wrong placements

5. Inventory Counting Staff Interface

Counting Tasks → Location Scan → Product Scan → Count Entry → Variance Reporting → Supervisor Review

• Scheduled counting tasks
• Location-based counting workflows
• Variance calculation and reporting
• Adjustment request workflows
• Historical count comparison

Core Workflow Automation

Intelligent Order Processing

• Dynamic Priority Scoring: Configurable rules based on customer type, order value, shipping urgency
• Zone-based Order Splitting: Automatic division by warehouse zones
• Batch Creation: Optimized "Basket" creation for picking efficiency
• Staff Assignment: Intelligent allocation based on location and workload

Quality Control System

• Mandatory quantity verification before packaging
• Real-time discrepancy logging and blocking
• Automated recount requests
• Packaging authorization only after validation

Shipping & Tracking

• Automated carrier selection and label generation
• Tracking number registration in PrestaShop
• Real-time status updates and customer notifications

Technical Features

Barcode System Integration

• Support for multiple barcode types (EAN-13, UPC, Code 128, QR)
• Mobile camera barcode scanning
• Dedicated barcode scanner device compatibility
• Barcode generation for internal batches and packages
• Scan history and audit trails

Handheld Interface Optimization

• Responsive Design: Works on various screen sizes (phones, tablets, dedicated scanners)
• Touch-Optimized UI: Large buttons, minimal typing required
• Offline Functionality: Local data storage with background sync
• Battery Optimization: Efficient operation for full-shift use
• Fast Scanning: Quick response times (< 0.5 seconds)

Real-time Synchronization

• Web-to-mobile data sync
• Mobile-to-web status updates
• Conflict resolution for offline edits
• Push notifications for urgent tasks
• Activity logging and monitoring

User Roles & Permissions

Warehouse Operator Roles

1. Order Picker: Batch picking and consolidation
2. Quality Controller: Quantity verification and discrepancy handling
3. Packager: Packaging and shipping preparation
4. Stock Handler: Product placement and organization
5. Inventory Counter: Regular stock counting and adjustment
6. Supervisor: Oversight, approval, and exception handling

Permission Management

• Role-based access control
• Zone-specific permissions
• Task assignment restrictions
• Approval workflow configurations
• Audit trail and activity monitoring

Performance Tracking & Compensation System

Activity Monitoring & Statistics

• Real-time Activity Logging: All employee activities (picking, counting, packaging, stocking) logged with timestamps
• Performance Metrics:
  • Number of orders processed per shift
  • Operation speed (items per hour)
  • Work accuracy (error-to-success ratio)
  • Productivity by zone/section
• Manager Dashboard: Display of individual and team performance statistics
• Comparative Reports: Performance comparison between employees and teams

Compensation Calculation

• Task-based Payment: Wage calculation based on:
  • Number of batches picked
  • Number of recounts completed
  • Number of packages prepared
  • Number of products stocked
• Variable Rate System: Different rates for:
  • Different tasks (picking vs. counting)
  • Different times (regular shift, overtime, holidays)
  • Skill levels (regular employee, supervisor)
• Automated Payroll Integration:
  • Automatic weekly/monthly wage calculation
  • Precise recording of work hours and activities
  • Payroll file generation
  • Financial department reporting

Incentive & Bonus Systems

• Performance Bonuses: Rewards for:
  • Achieving production targets
  • High accuracy (low error rate)
  • Above-average operation speed
• Quality Incentives: Rewards for error reduction
• Attendance Rewards: Bonuses for regular and punctual attendance

Reporting & Transparency

• Employee Portal: Access to personal performance statistics
• Real-time Earnings Display: Live display of calculated wages
• Dispute Resolution: System for registering disputes and activity reviews
• Historical Data: Storage of performance and payment records

Efficiency Improvements

• 90% Reduction in Manual Errors: Automated validation eliminated most human data entry errors
• 65% Faster Order Processing: Optimized workflows reduced processing time
• 40% Reduction in Labor Costs: Automation reduced manual intervention requirements
• 95% Order Accuracy: Quality control processes ensured high accuracy rates

Operational Improvements

• Real-time inventory accuracy
• Reduced misplacement and picking errors
• Faster order fulfillment cycles
• Better staff productivity tracking
• Enhanced customer satisfaction

Technical Stack

Core Platform

• E-commerce: PrestaShop 1.7+
• Backend: PHP 8+, MySQL 8+, Redis for caching
• Mobile Interface: Progressive Web App (PWA) technology
• APIs: RESTful API for mobile communication

Integration & Hardware

• Barcode Scanners: Support for Bluetooth, USB, and camera-based scanning
• Printers: Thermal label printers for shipping labels
• Mobile Devices: Android and iOS compatibility
• Carrier APIs: Integration with major shipping providers

Security Features

• Device registration and authentication
• Secure data transmission (HTTPS/TLS)
• Session management and timeout
• Data encryption at rest
• Regular security updates

Implementation Features

Installation & Setup

• Single PrestaShop module installation
• Guided configuration wizard
• Device setup instructions
• Staff training materials

Maintenance & Support

• Automatic updates through PrestaShop
• Performance monitoring dashboard
• Error reporting and diagnostics
• Regular backup and recovery
• Scalable architecture for business growth

Project Outcomes

• Complete warehouse automation solution for PrestaShop
• Optimized mobile interfaces for all warehouse roles
• Significant error reduction through barcode validation
• Real-time inventory accuracy and tracking
• Scalable system supporting business expansion
• Comprehensive reporting and analytics suite

This warehouse management system combines PrestaShop integration with optimized handheld interfaces to create a seamless, error-resistant workflow. The barcode-centric design and role-specific mobile applications transformed manual warehouse operations into efficient, digital processes while maintaining full synchronization with the e-commerce platform.