Leading Genset Manufacturer × Aetos Digilog — Case Study
Case Study · Manufacturing WMS
From 2 Warehouses to 6 — A Leading Genset Manufacturer’s Five-Year Supply Chain Transformation
How India’s leading power equipment manufacturer replaced Excel-driven chaos with a fully integrated WMS — and scaled their warehouse network 3× without adding operational complexity.
Industry
Power Equipment Manufacturing
Facilities
6 Warehouses Across India
SKUs Managed
10,000+
Solution
Warehouse Design + WMS
Partnership
5 Years & Counting
0%
Inventory Accuracy
0%
OTIF Improvement
2→6
Warehouses Scaled
10K+
SKUs Under Control
About the Client
India’s Leading Power Equipment Manufacturer
India’s leading genset manufacturer produces Silent Diesel Gensets, transformers, switchgear, and industrial engines — running multiple manufacturing plants across India, dispatching to a wide network of distributors and end consumers at scale.
Every new facility onboarded on the same platform — no re-implementation, no disruption.
2
Year 1
Go-Live
3
Year 2
3rd Facility
4
Year 3
Scale Up
5
Year 4
5th Location
6
Today
6 Live
The Challenge
When Growth Outpaces Your Systems
The client had invested heavily in racked warehousing and physical infrastructure — but without a digital backbone to match. The result: a growing gap between operational scale and operational control.
01
Inventory Blind Spots at Scale
With 10,000+ SKUs across multiple plants, real-time inventory position was unknown. Discrepancies surfaced at month-end audits — not in time to act. Obsolescence crept in silently as slow-moving parts occupied prime locations with no visibility.
02
Dispatch Bottlenecks Post-GST
High-throughput distributor and consumer dispatches were managed manually. Post-GST compliance added documentation complexity that Excel and paper-based processes couldn’t absorb without slowing fulfilment.
03
Racked Infrastructure, No Layout Logic
Significant investment in racked warehousing — but items were placed ad hoc, picking paths were long and unguided, and order servicing time lagged behind what the infrastructure should have been capable of.
04
Reactive Replenishment, No Forecasting
Stock replenishment was triggered by stockouts, not demand signals. Procurement and warehouse teams were perpetually firefighting with no alert system or analytics layer to plan ahead.
Our Approach
We Redesigned the Warehouse Before We Touched the Software.
Aetos’s engagement started on the warehouse floor. Before configuring a single workflow, we mapped the physical space, understood SKU movement patterns, and designed the infrastructure the WMS would run on.
🏗️
Warehouse Transformation
Physical redesign before digital deployment
📐
Step 01
Warehouse Mapping & Zone Design
Walked every facility. Mapped floor space, aisle widths, dock positions, and ceiling height. Designed zones aligned to SKU velocity — fast-movers nearest dispatch, bulk storage to the rear.
🗂️
Step 02
Racking Placement & Bin Logic
Advised on racking placement to maximise cubic utilisation. Defined bin structures — each SKU assigned a fixed home location based on size, weight, pick frequency, and dispatch priority.
⚙️
Step 03
WMS Built Around the Layout
Every zone, aisle, rack, and bin configured into Aetos WMS. The system mirrors the physical warehouse exactly — guided putaway, optimised pick paths, location-based alerts.
⚠ Before Aetos
Items placed wherever space was available — no zone or bin logic
Racking investments underutilised, no structured putaway
Manual stock counts, discrepancies found after dispatch
No visibility into slow-movers or obsolete stock locations
✓ After Aetos
Defined zones: velocity-based, product-type-based, dispatch-aligned
Every rack and bin mapped — system-guided putaway from day one
Optimised pick routes, shorter walks, faster order fulfilment
Scan-driven accuracy — discrepancies caught at point of transaction
Live aging dashboards — management acts on data, not gut feel
The Solution
A WMS Built for Manufacturing at Scale
With the warehouse physically optimised, Aetos deployed a full WMS stack — configured to the client’s SOPs, SKU structures, distributor workflows, and GST compliance requirements across all 6 facilities.
📍
Real-Time Inventory Tracking
Bin-level stock visibility across all 6 warehouses
Real-time inbound and outbound scanning
Stock aging and slow-mover alerts
Obsolescence prevention through location intelligence
🚚
Automated Dispatch Management
Digitised outward logistics for distributor dispatches
GST-compliant documentation integrated into workflows
Automated pick list generation and guided picking
OTIF tracking with live dispatch dashboards
🔔
Alert-Based Replenishment
Reorder point alerts triggered by live stock levels
Demand forecasting layer for forward planning
Procurement signal visibility for purchase teams
Exception-based notifications — act before stockout
📊
Analytics & Decision Layer
Inventory accuracy and fill-rate KPI dashboards
Worker productivity tracking per location, per shift
Supply chain optimisation insights for leadership
Multi-facility consolidated reporting
Results
Numbers That Changed How They Operate
Measurable impact from day one — sustained and compounded over five years of partnership.
0%
Inventory Accuracy
Scan-driven processes replaced manual counting
0%
OTIF Improvement
On-Time-In-Full delivery performance uplift
3×
Warehouse Scale
From 2 to 6 facilities — same platform, zero re-implementation
5 Yrs
Continuous Partnership
Longest-running manufacturing client on Aetos
“Aetos gave us real-time control over inventory and dispatch that we simply didn’t have before. The combination of warehouse design and the WMS means the system reflects exactly how our operations actually work — not a generic template we had to adapt to.”
GB
Gopal B.
Logistics Manager, Leading Genset Manufacturer · G2 Verified Review
★★★★★
5.0 · G2 Verified
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We Start on Your Floor, Not on a Screen.
Aetos maps your physical warehouse, designs the layout, and builds the WMS around your actual operations. 30 minutes. No pitch. Just a diagnosis.
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