🏭 WMS (Warehouse Management System) - Rails Application

A comprehensive warehouse management system built with Rails 8 for complete inventory and fulfillment operations

🎯 What is this project?

This is a complete Warehouse Management System (WMS) designed to help you manage inventory, fulfillment, and warehouse operations efficiently. It includes all essential features for professional warehouse management, from multi-location inventory tracking to pick list optimization.

⚡ Why use this WMS?

• 🚀 5-minute setup - Uses Docker and devcontainers for development without complex configurations
• 📦 Multi-warehouse - Support for multiple warehouses, zones, and locations
• 📊 Real-time tracking - Complete inventory transaction audit trail
• 🎯 Pick optimization - Intelligent pick list generation and route optimization
• 📱 Responsive - Modern design with Tailwind CSS for mobile warehouse operations
• 🔐 Secure - Complete admin panel with role-based access
• 📈 Analytics - Comprehensive WMS dashboard with KPIs and alerts
• ✅ Tested - Complete test suite with RSpec and security scanning

---

🏭 Main WMS Features

Warehouse Management

• 🏢 Multi-warehouse support with hierarchical organization
• 🏗️ Zone management (receiving, storage, picking, packing, shipping)
• 📍 Location tracking with coordinate system and capacity management
• 📊 Utilization monitoring with real-time capacity alerts
• 🎯 Location optimization for efficient space usage

Inventory Management

• 📦 Multi-location inventory with real-time tracking
• 🏷️ Batch/lot tracking with expiry date management
• 📈 Stock reservations and allocation management
• ⚖️ FIFO/LIFO/FEFO inventory allocation methods
• 🔄 Inventory transactions with complete audit trail
• 📋 Cycle counting for inventory accuracy
• ⚠️ Low stock alerts and automatic replenishment

Order Fulfillment

• 📋 Pick list generation with route optimization
• 🎯 Task management (putaway, picking, replenishment, cycle count)
• 📦 Order processing with warehouse assignment
• 🚚 Shipment tracking and fulfillment status
• ⏱️ Performance metrics and completion time tracking

Analytics & Reporting

• 📊 Real-time dashboard with WMS KPIs
• 📈 Inventory valuation and movement reports
• 🎯 Task performance and productivity metrics
• 📦 Pick list efficiency and route optimization
• ⚠️ Alert system for exceptions and low stock

Technical Architecture

• 🚀 Rails 8.0.2 with latest improvements and performance optimizations
• 🐘 PostgreSQL with comprehensive indexing for WMS operations
• ⚡ Stimulus + Turbo for real-time warehouse operations
• 🎨 Tailwind CSS with responsive design for mobile warehouse operations
• 🔄 Background jobs (Sidekiq) for inventory synchronization and optimization
• 🏗️ Service objects for complex WMS business logic
• 🐳 Docker with devcontainers for consistent development
• 🧪 RSpec comprehensive test suite with 289 examples
• 🔒 Brakeman security scanning (0 vulnerabilities)
• 📊 Performance monitoring with 35+ database indexes

---

🚀 Quick Start

1. Prerequisites

# Install Docker
https://www.docker.com/

# Install Devcontainers CLI
npm install -g @devcontainers/cli
# or with npx
npx install -g @devcontainers/cli

2. Clone and run

# Clone the repository
git clone https://github.com/AlanAlvarez21/ruby-wms-boilerplate.git
cd ruby-wms-boilerplate

# Build the container (includes DB setup)
bin/build_container

# Seed the database with sample data
bin/rails db:seed

# Start the application
bin/dev

3. Ready! 🎉

• WMS Dashboard: http://localhost:3000/admin
• System Users:
  • Admin: admin@wmsapp.com / password123 (Full system access)
  • Operador: operador@wmsapp.com / password123 (Production Orders + Products + Manual Printing)
  • Supervisor: supervisor@wmsapp.com / password123 (Warehouse management)
  • Picker: picker@wmsapp.com / password123 (Task execution)
• Sample Data Includes:
  • 2 Warehouses with 10 zones and 90 locations
  • 15 Products with WMS fields (SKU, dimensions, reorder points)
  • 4 System users with different roles and permissions
  • 10 Sample tasks (picking, putaway, replenishment, cycle count)
  • Inventory transactions and movement history

---

📁 WMS Project Structure

├── app/
│   ├── controllers/
│   │   ├── admin/
│   │   │   ├── warehouses_controller.rb      # Warehouse management
│   │   │   ├── zones_controller.rb           # Zone management
│   │   │   ├── locations_controller.rb       # Location management
│   │   │   ├── tasks_controller.rb           # Task assignment & tracking
│   │   │   ├── pick_lists_controller.rb      # Pick list management
│   │   │   ├── inventory_transactions_controller.rb
│   │   │   └── ...
│   │   └── admin_controller.rb       # WMS Dashboard
│   ├── models/
│   │   ├── warehouse.rb              # Multi-warehouse support
│   │   ├── zone.rb                   # Zone management (receiving, storage, etc.)
│   │   ├── location.rb               # Location tracking with coordinates
│   │   ├── task.rb                   # Task management system
│   │   ├── pick_list.rb              # Pick list optimization
│   │   ├── pick_list_item.rb         # Individual pick items
│   │   ├── inventory_transaction.rb  # Inventory audit trail
│   │   ├── product.rb                # Enhanced with WMS fields
│   │   ├── stock.rb                  # Multi-location inventory
│   │   ├── order.rb                  # Warehouse fulfillment
│   │   └── ...
│   ├── services/
│   │   ├── inventory_service.rb      # Stock allocation & movement
│   │   └── pick_list_service.rb      # Route optimization
│   ├── jobs/
│   │   ├── inventory_sync_job.rb     # Background inventory sync
│   │   └── pick_list_optimization_job.rb
│   ├── helpers/
│   │   └── wms_helper.rb             # WMS-specific view helpers
│   └── views/
│       └── admin/                    # WMS admin interface
├── db/
│   ├── migrate/                      # 15 WMS-specific migrations
│   └── seeds.rb                      # Complete WMS sample data
└── spec/                             # Comprehensive test suite

---

🏭 WMS Configuration

1. Environment Variables

# Database configuration
export DATABASE_URL="postgresql://user:password@localhost:5432/wms_development"

# Rails configuration  
export RAILS_ENV="development"

# Background job processing
export REDIS_URL="redis://localhost:6379"

2. Warehouse Setup

The system comes with sample warehouses, but you can customize:

# In db/seeds.rb or through admin interface
warehouse = Warehouse.create!(
  name: "Main Distribution Center",
  code: "MDC",
  address: "123 Warehouse St, City, State"
)

# Add zones
receiving_zone = warehouse.zones.create!(
  name: "Receiving",
  code: "RCV",
  zone_type: "receiving"
)

# Add locations
receiving_zone.locations.create!(
  aisle: "A",
  bay: "01", 
  level: "01",
  capacity: 1000
)

---

🛠️ Development Commands

# Development
bin/dev                     # Server + Tailwind watcher
bin/rails server            # Rails server only
bin/rails tailwindcss:watch # Tailwind watcher only

# Database
bin/rails db:create         # Create database
bin/rails db:migrate        # Run migrations
bin/rails db:seed           # Seed with sample data
bin/rails db:reset          # Reset and seed

# Testing
bundle exec rspec           # Run tests (289 examples)
bin/brakeman               # Security analysis (0 vulnerabilities)
bin/rubocop                # Code linting

# WMS Operations
# (Sidekiq jobs removed - using ActiveJob inline adapter)

# Assets
bin/rails assets:precompile # Compile assets for production
bin/rails tailwindcss:build # Build Tailwind CSS

---

🎨 WMS Customization

1. Warehouse Layout Customization

# Configure zone types for your operation
Zone::ZONE_TYPES = %w[receiving storage picking packing shipping returns]

# Customize location coordinate system
Location.create!(
  zone: zone,
  aisle: "A",      # Aisle identifier
  bay: "01",       # Bay number within aisle  
  level: "01",     # Level/shelf within bay
  capacity: 1000   # Weight or volume capacity
)

2. Inventory Allocation Methods

# In app/services/inventory_service.rb
# Customize allocation strategy
ALLOCATION_METHODS = {
  fifo: -> { order(:created_at) },           # First In, First Out
  lifo: -> { order(created_at: :desc) },     # Last In, First Out  
  fefo: -> { order(:expiry_date) }           # First Expired, First Out
}

3. Task Types and Priorities

# Customize task types for your warehouse operations
Task::TASK_TYPES = %w[putaway picking replenishment cycle_count receiving shipping]
Task::PRIORITIES = %w[low medium high urgent]

4. WMS Translations

# In config/locales/es.yml (Spanish included)
es:
  wms:
    warehouse: "Almacén"
    pick_list: "Lista de Picking"
    task: "Tarea"
    inventory: "Inventario"

---

📊 WMS Administration Panel

The comprehensive WMS admin panel includes:

Dashboard & Analytics

• 📈 WMS Dashboard: Real-time KPIs, warehouse utilization, alerts
• 📊 Inventory Analytics: Stock levels, movement reports, valuation
• 🎯 Task Metrics: Performance tracking, completion rates, overdue alerts
• 📋 Pick List Analytics: Route efficiency, completion times

Warehouse Operations

• 🏢 Warehouse Management: Multi-warehouse CRUD with utilization metrics
• 🏗️ Zone Management: Receiving, storage, picking, packing, shipping zones
• 📍 Location Management: Coordinate tracking, capacity management
• 📦 Stock Management: Multi-location inventory with batch/lot tracking

Task & Fulfillment

• 🎯 Task Assignment: Putaway, picking, replenishment, cycle count tasks
• 📋 Pick List Management: Route optimization, progress tracking
• 📦 Order Processing: Warehouse assignment, fulfillment status
• 🚚 Shipment Tracking: Outbound logistics management

Inventory Control

• 🔄 Transaction History: Complete audit trail with filtering
• 📊 Movement Reports: Inventory flow analysis with CSV export
• ⚠️ Alert System: Low stock, expired products, overstock warnings
• 🏷️ Batch Tracking: Lot management with expiry date monitoring

Access Control

• URL: /admin
• Authentication: Devise with role-based user management
• User Roles:
  • Admin: Complete system access
  • Operador: Production orders, products, manual printing
  • Supervisor: Warehouse operations management
  • Picker: Task execution and inventory updates
• Security: Role-based permissions, Brakeman scanned (0 vulnerabilities)
• Responsive: Mobile-optimized for warehouse floor operations

---

🧪 Testing

Complete test suite:

# Unit tests
bundle exec rspec spec/models/

# Controller tests
bundle exec rspec spec/controllers/

# Request tests
bundle exec rspec spec/requests/

# System tests (E2E)
bundle exec rspec spec/system/

# Coverage report
open coverage/index.html

---

🚀 Deployment

Heroku

# Create application
heroku create your-store

# Configure variables
heroku config:set RAILS_MASTER_KEY=your_master_key
heroku config:set MERCADOPAGO_ACCESS_TOKEN=your_token

# Deploy
git push heroku main

# Initial setup
heroku run rails db:migrate
heroku run rails db:seed

🎯 WMS Seeds summary: 🏢 Warehouses: 2 🏗️ Zones: 10 📍 Locations: 90 📦 Products: 15 (with WMS fields) 📊 Stock entries: 15 (multi-location) 🎯 Tasks: 10 (various types) 📋 Pick lists: Sample data 🔄 Inventory transactions: Movement history 👤 Admin users: 1

🔐 System credentials: Admin: admin@wmsapp.com / password123 Operador: operador@wmsapp.com / password123 (Orders + Products + Manual Printing) Supervisor: supervisor@wmsapp.com / password123 (Warehouse Management) Picker: picker@wmsapp.com / password123 (Task Execution)

Docker Production

# Build image
docker build -t your-store .

# Run
docker run -p 3000:3000 \
  -e RAILS_ENV=production \
  -e DATABASE_URL=postgres://... \
  your-store

---

🤝 Contributing

1. Fork the repository
2. Create a feature branch (git checkout -b feature/AmazingFeature)
3. Commit your changes (git commit -m 'Add some AmazingFeature')
4. Push to the branch (git push origin feature/AmazingFeature)
5. Create a Pull Request

---

📝 Ideal Use Cases

This WMS is perfect for:

• 🏭 Manufacturing facilities with complex inventory tracking needs
• 📦 Distribution centers requiring multi-location inventory management
• 🚚 3PL providers managing inventory for multiple clients
• 🏪 Retail operations with multiple warehouses and stores
• 💊 Pharmaceutical companies requiring batch/lot tracking and expiry management
• 🍕 Food & beverage operations with FEFO inventory rotation
• 🔧 Spare parts management with precise location tracking
• 📱 E-commerce fulfillment requiring pick optimization
• 🏗️ Construction supply with bulk inventory and location management
• 👨‍💻 Developers needing a professional WMS foundation

---

📋 WMS Roadmap

Completed Features:

• 🏢 Multi-warehouse management with zones and locations
• 🔄 Complete inventory transaction audit trail
• 🎯 Task management system with assignment and tracking
• 📋 Pick list generation with route optimization
• 🏷️ Batch/lot tracking with expiry date management
• 📊 Comprehensive WMS dashboard with real-time metrics
• ⚖️ FIFO/LIFO/FEFO inventory allocation methods
• 🔄 Background jobs for inventory sync and optimization
• 📱 Mobile-responsive design for warehouse operations

Recently Added:

• 🔍 Advanced search and filtering system
• 🔔 Notification system for alerts and updates
• 📱 API endpoints for mobile warehouse applications

Future Enhancements:

• 📊 Advanced analytics and machine learning insights
• 🤖 AI-powered demand forecasting
• 📱 Native mobile app for warehouse operations
• 🏷️ RFID and barcode scanning integration
• 🚚 Advanced shipping carrier integrations
• 📦 Automated replenishment recommendations
• 🌍 Multi-language interface expansion
• 🔄 Integration with ERP systems (SAP, Oracle, etc.)

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📄 License

This project is under the MIT license. See LICENSE for more details.

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🆘 Support

• 📖 Documentation: Project Wiki
• 🐛 Issues: Report problems
• 💬 Discussions: GitHub Discussions

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🏭 Deploy your WMS today! This comprehensive system saves you months of warehouse management development.