Legacy .NET Modernization to a Custom Warehouse Management System

Problem: The legacy .NET application only ran on a desktop, so the warehouse floor could not use it on handheld scanners.

Result: single responsive Angular web app on a rebuilt .NET API replaced it. The app runs on both desktop and the handheld scanner's browser. TwinCore migrated it module by module, while the old system stayed live. The floor and the office now use one codebase instead of a desktop tool plus paper at the racks.

Problem: Operators picked whichever lot was convenient, so older stock sat until it expired and got written off.

Result: With FEFO mode active, pick orders are routed to the lot with the earliest expiry date first, ranked per SKU. On the scanner the picker reads one line (bin, lot, days-to-expiry) instead of choosing from a lot list. Earliest-expiry lots clear before they reach the disposal window.

Problem: The old system tracked one quantity per SKU, with no record of which lot sat in which bin.

Result: Stock is tracked to rack, bin, and lot, with on-hand, reserved, and available split out per SKU. Putaway directs each pallet to a specific bin. No pick pulls a lot without its expiry attached.

Problem: Inbound deliveries were checked in on paper, so discrepancies surfaced days later, not at the dock.

Result: Receiving runs against scheduled dock doors, compares expected vs received per line, flags late inbound POs, and places pallets on QC hold before they enter pickable stock. Delayed and short deliveries are visible the moment they arrive, not at month-end reconciliation.

Problem: Reorders depended on someone noticing a shelf was getting low.

Result: The replenishment view lists every SKU below its minimum threshold, suggests an order quantity, and attaches supplier and lead days, with a one-click replenishment order to the right supplier. Stockouts on fast movers drop because critical items surface before they hit zero.

Problem: Accurate counts meant stopping the warehouse for a full physical inventory.

Result: Count plans scope to one area or category, move through scheduled / in-progress / completed, and record variance per plan. Counting runs area by area while picking continues, so the line never stops.