Overcoming Legacy System Integration Challenges

Integrating Legacy Systems with Modern Warehouse Control Systems (WCS)

When it comes to integrating legacy systems with modern Warehouse Control Systems (WCS) and automation platforms, warehouse operators face unique challenges. For a retail apparel distributor, these everyday concerns will typically include:

• High SKU (Stock Keeping Unit) variety
• Rapid seasonal changes
• Complex fulfillment channels (e.g., retail, e-commerce, and wholesale)

As these businesses attempt to modernize their operations, they must ensure that their outdated systems—such as an older Enterprise Resource Planning (ERP) system or basic Warehouse Management System (WMS)—can work in harmony with new, cutting-edge technologies.

A Retail Apparel Scenario

Imagine a retail apparel distributor that has been using an outdated WMS for over a decade. This WMS was designed to handle a limited number of SKUs, simple fulfillment processes, and static inventory management. However, as the business grows and expands its e-commerce operations, they decide to implement a modern Warehouse Control System (WCS) to automate key areas like picking, sorting, and packing in order to keep up with increasing order volumes.

Integrating the new WCS with the older WMS presents a significant challenge because the two systems are built on entirely different platforms, with different data structures and communication protocols. The outdated WMS can’t easily “talk” to the WCS, which is designed for real-time, high-speed data processing. This creates several operational issues:

Issue 1: Data Silos

The legacy WMS may store inventory data in batch files or static databases, making it difficult to share accurate, up-to-the-minute inventory information with the WCS. For instance, if the WMS isn’t updated in real-time, the WCS may pick items that are out of stock, leading to fulfillment errors and costly delays.

Issue 2: Order Fulfillment Delays

Without smooth integration, information on incoming orders may not flow efficiently between the systems. A sales order placed on the e-commerce platform might get stuck in the ERP and not reach the WMS and WCS in a timely manner, delaying the fulfillment process. This is especially problematic during peak seasons like holiday sales or product launches, where even small delays can cause major bottlenecks.

Issue 3: Inefficient Pick and Sort Processes

Modern WCS solutions use advanced algorithms for optimizing picking routes and sortation, reducing travel time and labor costs. However, the outdated WMS might not be capable of sending real-time inventory locations to the WCS, making these optimizations less effective.

Communication Breakdown Costs Add Up Fast

Imagine a customer orders a popular pair of jeans from the distributor’s e-commerce platform. The WMS, which updates inventory only once every 12 hours, shows that the jeans are in stock. However, the actual stock level has already been depleted due to in-store purchases and other online orders.

Because the WMS and WCS aren’t integrated to share real-time inventory data, the WCS picks and packages the jeans, only for the customer to be notified days later that their order can’t be fulfilled.

This not only leads to customer dissatisfaction but also creates inefficiencies in the warehouse as staff waste time picking items that aren’t available. Additionally, handling returns, issuing refunds, and reshipping other items becomes a logistical nightmare, adding extra operational costs.

How to Overcome System Integration Complexity

To avoid these issues, warehouse operators need a well-thought-out integration strategy. Here’s how they can address system integration complexity:

API-Based Integration‍

Many modern WCS solutions like our Cornerstone software offer APIs (Application Programming Interfaces) that allow legacy systems to connect and communicate with them. Leveraging APIs can help synchronize data such as inventory levels, order status, and shipping information, ensuring both systems stay up-to-date.

Data Mapping and Cleansing

Before integration, data from the legacy WMS may need to be cleaned and mapped to align with the modern WCS. This involves creating a unified data format that both systems can understand, eliminating discrepancies between the information stored in each system.

Phased Rollout

Instead of overhauling everything at once, companies can implement integration in phases. For example, they might start by integrating order management processes and then move on to inventory and fulfillment. This reduces disruption and gives time to troubleshoot issues as they arise.

End-to-End Testing

Thorough testing of the integrated systems is crucial before full deployment. Running simulated order fulfillment cycles can help identify any disconnects between the WMS and WCS, allowing operators to address them proactively before real-world orders are affected.

Plan For Your WCS Modernization

By focusing on proper integration planning, distribution centers can create a seamless flow of data between their legacy systems and new automation platforms, reducing the risk of operational inefficiencies and improving both speed and accuracy in the fulfillment process.

Looking for an expert partner to help streamline your warehouse operations? Tompkins Solutions has over 40 years of experience in supply chain integration and warehouse automation. Contact us today to learn how we can help your business grow efficiently.