Your in-depth guide to WMS testing processes

Warehouse management system (WMS) implementation is complex and comes with many chances for something to go wrong. Effective testing is essential to identify and mitigate risks, ensuring smooth integration and efficient operations

One of the biggest threats comes during the testing phase. If you miss a step, integration, or report you need and move forward with the selection process, then you’ll have to engineer an update to your new system, expanding cost and the time it takes to have a proper tool.

That's why we’ve put together a list of seven steps and recommendations to help you understand the processes and areas to consider when performing your WMS testing.

1. Create virtual warehouse location(s) with sample data

Begin by creating a virtual warehouse environment and populate it with representative goods and inventory data. This step can be done from scratch, or you can export item files from your existing systems and upload them to your test platform. If data from other systems is expected to integrate with the new WMS, address these integrations early on to reduce the risk of data synchronization errors during go-live.

2. Test integration with partner systems and virtual clients

At a minimum, you’ll want to be able to see how the WMS will process inbound and outbound electronic data interchanges (EDI). This is a good chance to check which EDIs your potential WMS supports in real-world scenarios, not just in the vendor’s marketing materials.

3. Run through a complete order test

Here it’s time to pair people with the system. Fabricate a new order starting with its receipt in your e-commerce, sales, CRM, ERP, or another platform. Observe as the system processes the order and generates picking and packing instructions. Employees should interact with the WMS using handheld scanners or other hardware to process and return picking data. Verify label generation, carrier integration, and that all order details remain unified and accurate throughout.

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4. Cut your digital inventory levels to test replenishment functions

In your virtual warehouse, remove goods slowly through digital orders to see when the system’s replenishment features kick on and what levels it recommends. Testing both regular and unexpected scenarios helps verify that the system can adapt to fluctuations and unique circumstances.

5. Perform a cycle counting run

A new WMS can save you lots of time and money if you’re automating processes, especially your inventory counts. Use your warehouse and inventory to perform a cycle count and verify that it’s accurate.

You might want to test all of the cycle counting settings it offers and see how long they take. This should allow you to plan for full or partial inventory counts — based on things like how often different goods are sold — to minimize disruption while still keeping tabs on your most important inventory.

6. Review quality assurance (QA) tools

Depending on your deployment and the WMS you’re testing, there could be multiple QA functions available to you. Review the checks in separate processes to see how they fit with your existing workflow.You’ve already performed a variety of other tests at this point. Check those results and see if QA measures were taken during the processes and verify their results as well as the need.

7. Run your specialty programs and functions

Does your business have unique requirements or use specialty equipment in the warehouse? Review these instances and modules to ensure that you’re in good shape with the new WMS.

Even if you don’t have highly specialized requirements, verify compatibility with all equipment types, such as barcode scanners and material handling systems. This step ensures that all critical functions and data-sharing protocols are operational.

By following these steps, you’ll ensure a comprehensive WMS testing process that captures essential functionalities, integration points, and workflows. Vigilant testing reduces post-launch issues and helps ensure that your WMS delivers a return on investment without unexpected disruptions.