Pyrops WMS - Serialised & Batch-Tracked Inventory
Every Unit. Tracked. From Inbound to Last Mile.
Serialised and batch-tracked inventory is where warehouse management gets genuinely complex. One wrong serial number, one FEFO violation, one untracked batch – and the consequences land in warranty claims, compliance failures, or product recalls. Pyrops manages the complexity so your team does not have to.
Serial Number Capture & End-to-End Tracking
Every serialised unit is scanned and registered at inbound receipt – linked to supplier, purchase order, batch, and production details. From that moment, the serial number is tracked through every warehouse movement: putaway, transfer, pick, pack, and dispatch. The system always knows exactly where every serial number is and where it has been.
Serial tracking delivers:
- Serial number captured at GRN by barcode or QR scan - no manual entry
- Linked to supplier, PO, batch, production date, and shelf life at registration
- Tracked through every movement - putaway, transfer, pick, pack, dispatch
- Bi-directional trace: where is serial X now? Where has it been since inbound?
FEFO / FIFO / FMFO - Structural Enforcement at Pick
FEFO enforcement in Pyrops is structural. The system selects the nearest-expiry batch and directs the picker to the specific bin. If the picker scans a different batch, the transaction is rejected. Supervisor override requires authentication and a logged reason code. Compliance cannot be bypassed by picker experience or habit – it is enforced by the workflow.
Structural FEFO delivers:
- FEFO, FIFO, and FMFO configurable per SKU or SKU category
- System-directed batch selection - picker has no discretion
- Override requires authentication and a logged reason code for audit
- Every batch pick decision logged: user, timestamp, batch selected, reason if override
Shelf-Life Monitoring & Automatic Expiry Management
Pyrops tracks shelf life at the batch level from the moment of GRN. As batches approach their expiry date, Pyrops surfaces alerts at configurable thresholds – giving planners time to prioritise near-expiry stock before it becomes a write-off. Batches past the configured threshold are automatically removed from the pickable pool without manual intervention.
Shelf-life monitoring delivers:
- Expiry date tracked per batch from GRN - no manual expiry register
- Configurable alert thresholds - 30 days, 60 days, or custom per SKU or category
- Automatic quarantine when batch crosses the non-pickable threshold
- Near-expiry dashboard - planners see at-risk stock in real time across all locations
Licence Plate Operations (LPN) - Move Groups Efficiently
Licence Plate Numbers allow groups of serialised units – a pallet, a case, a tote – to be moved as a single tracked entity with one scan. This eliminates individual scanning at every movement, dramatically reducing the scan burden on floor teams without losing unit-level traceability at any point in the process.
LPN operations deliver:
- LPN created at inbound - links to all serial numbers on the pallet or case
- Single LPN scan moves the entire group through the warehouse efficiently
- Serial-level detail preserved - accessible by drilling into the LPN at any time
- LPN split and merge supported - full traceability maintained through all LPN changes
Device State Machine for Serialised Asset Lifecycles
For electronics, hi-tech products, and serialised assets with operational lifecycles, Pyrops tracks each device through a configured state machine – Active, Returned, In-QC, In-Refurb, Restocked, Redeployed, Disposed. Every state transition is logged with user, timestamp, and location. Deployed at scale for operations managing millions of serialised devices simultaneously.
Device State Machine for Serialised Asset Lifecycles — Key Points
- Configurable states and transitions defined per device type and operation
- Every state transition logged: user, timestamp, reason, and current location
- Device state visible in real time - no manual status tracking required
- Deployed at operations managing millions of serialised devices across multiple facilities
Full Serial & Batch Traceability Capabilities
Serial Number Tracking
Captured at inbound, tracked through every movement to final dispatch.
FEFO Enforcement
Structural compliance - system-enforced at pick, not picker-dependent.
Shelf-Life Monitoring
Near-expiry alerts and automatic quarantine at configurable thresholds.
LPN Operations
Group movement with one scan - unit-level detail preserved throughout.
Device State Machine
Full serialised lifecycle from inbound to disposal - every transition logged.
Batch Traceability
Forward and backward lot trace in seconds - audit-ready export anytime.
QR Code Handling
Configurable QR code structures - multiple formats within one operation.
Batch Split & Merge
Manage batch splits at production and consolidations without traceability gaps.
Regulatory Audit Trail
Complete tamper-evident records exportable for compliance submissions.
ERP Sync
Batch and serial data syncs bi-directionally with your ERP in real time.
Structural FEFO
Compliance enforced at the workflow level - not dependent on picker knowledge.
Instant Lot Trace
Forward and backward traceability in seconds - no spreadsheet, no manual search.
Audit-Ready Records
Complete tamper-evident batch records exportable for regulatory submission.
Zero Manual Entry
Serial numbers captured by scan - no manual entry, no gaps in the record.
Millions of Devices
Device state machine deployed at operations managing millions of serialised units.
Your traceability should be instant and complete - always.
Talk to a Pyrops expert about your serial and batch inventory requirements. We will show you how structural enforcement works in practice – and what instant lot traceability looks like across your specific product types and operational scenarios.
Frequently Asked Questions
Pyrops directs every pick to the specific bin containing the nearest-expiry batch. The picker scans the location and item - if it does not match the system's selected batch, the scan is rejected. Supervisor override requires authentication and a logged reason code. Compliance is structural.
Batch tracking manages groups of units with a shared lot number, production date, and expiry date. Serial number tracking manages individual units with a unique identifier. Pyrops supports both simultaneously - a batch can contain multiple serialised units, each tracked individually within the batch context.
Yes. The device state machine tracks each serialised device from inbound receipt through forward dispatch, customer return, QC inspection, refurbishment, and redeployment. Every transition is logged. This is deployed at operations managing millions of devices.
LPNs group serialised units - a pallet or case - into a single trackable entity. Moving the LPN moves all serial numbers within it. The serial-level detail is preserved and accessible by drilling into the LPN at any point. LPN operations reduce scan burden significantly on high-volume serialised operations.