We’ve previously discussed the key steps for a successful WMS implementation, and one of those critical steps involves testing. WMS testing is the only way to ensure the system functions properly in real-world operations so that your business can succeed. More importantly, it’s an opportunity to test the system with realistic scenarios, as opposed to generically testing the WMS. While there are a wide range of tests to perform, they all fall under three main categories: system testing, performance testing, and integration testing.
In this post, we’ll go over WMS testing tips we believe are essential to getting your system running smoothly, within budget, and on time.
General WMS Testing Tips
- Test to break, not to prove
The first thing you want to remember is that testing is not done to ensure the system works, but to see where the system doesn’t work. Chances are, if you’ve tested the system and not found any errors, you haven’t done enough testing. You want to identify weaknesses and potential failures rather than confirm the system works. This is an opportunity to look for hidden defects and stress-test the system’s limits to ensure it can handle real-world applications. - Test the exceptions
Normal processes are easy to test, but the exceptions are what slow you down. Common exceptions include short picks (inventory not available), damaged inventory, receiving unplanned items, and inaccurate setup (e.g., incorrect box sizes). Even small percentages of errors can cause significant issues in high-volume operations. Testing the exceptions means you focus on more than just the “happy path,” where the system operates under normal process flows. The goal is to thoroughly test the kinds of situations that are less common but that could lead to significant issues down the line. - Test utilizing an organized tool
A simple testing tool ensures test scenarios are well-organized and tracked. The tool can be simple, such as Excel. Smart Sheet and Jira can provide more thorough support and effective communication. Tools that enable collaboration and allow team members to communicate are invaluable. An organized testing tool can include all necessary scenarios and exceptions and will allow team members to discuss testing in real time to catch any snags. While the testing tool is important, it is just as critical to ensure it is managed well, so no information falls through the cracks and individual testers understand their accountability in the process. - Test with prepared detailed data and reloading plans
When creating testing data, ensure it covers a range of real-world warehouse operations and interactions; it must be detailed and accurately reflect situations the warehouse will encounter once it’s live. The data must also simulate both small-scale operations and peak times when the warehouse is at full capacity. Include various data inputs, like product information (SKUs, UPC barcodes, weights, dimensions), inventory counts, order quantities, and customer information to test how the WMS handles different forms of data and ensure compatibility across formats.
During the business requirements phase, establish how you plan to load data into the system and let the vendor know what templates will look like so the information is available throughout training and implementation. By creating structured data templates, testing a broad range of scenarios, and resetting data for multiple runs, you can guarantee that the WMS is fully prepared for real-world challenges while making system adoption smoother for employees. - Test with prioritized teams and processes
Start by breaking the system’s processes into manageable segments that different teams can be responsible for. We recommend splitting the teams into receiving/inbound, outbound, and inventory management. These teams should be composed of those on the floor, who do the day-to-day work, and who will understand what components need to be tested thoroughly. This will not only ensure thorough testing but also help hold team members accountable. Individuals may claim to have completed testing and marked it as approved, despite not having conducted a comprehensive evaluation. Separation by teams and processes will help avoid the pitfalls of rushed testing. - Test by validating data accuracy thoroughly
Testers should review each screen to ensure that orders have been validated correctly and examine the transaction history to verify execution. The team should also use different testing and validation tools, such as SQL queries, to check data accuracy across multiple files. They must review the data displayed but also ensure that the underlying data has been properly updated and remains consistent throughout the system. Since the same information may be stored in multiple tables, consistency across all data sources must be verified throughout. - Test with streamlined communication and issue logging
Systematic tracking and communication during testing are essential. While a testing tool that allows users to provide feedback is helpful, it may not be sufficient for escalating issues. To address problems consistently, use an escalation point or an issue log. This is important because some issues may not be directly related to the test scenario but could involve other topics, making it necessary to document them in an issue log.
We all know that email is ineffective in tracking things well. The issue-tracking process needs to be integrated into the testing plan. As testing progresses and new complications arise, they should be added to the issue log. The focus should be on building a streamlined, effective communication system that everyone uses consistently. - Test with organization and ownership in mind
Testing takes time and effort, but more than anything, it takes planning. WMS complexity often arises from its interaction with multiple systems, so you want to take a systematic approach and test thoroughly. Careful planning ensures smooth coordination between multiple systems and helps avoid potential issues during implementation.
System testing prepares the system for real-world scenarios, reduces downtimes and errors, and increases user confidence in the system. The next category of testing is focused on how the system performs as a whole.
Integration Testing
While some operations may use a WMS as a standalone system, for most, it will serve as the control center for the many other systems the WMS integrates with, like ERP, TMS, and automation. Testing at this level is performed to ensure data is flowing smoothly between all systems. For example, to verify that when a warehouse worker scans a barcode in the WMS, the information is correctly transmitted to the ERP for order fulfillment, or when inventory data updates in the WMS, the TMS reflects those changes for shipment planning.
Integration testing is a deeper level of testing, which means many of the tests performed in system and performance testing will undergo the integration phase of testing to ensure all modules are working effectively with each other. However, two main tips rise to the top when it comes to integration testing.
- Simulate Complex Real-World Operations
Real-world operations are often messy and unpredictable. Simulating the complexity of actual business operations, where errors, delays, and miscommunications happen frequently is essential for integration testing. This is the only way to uncover how the operation will function as a whole. - Validate Data Accuracy Thoroughly
The same data validation process performed during the system testing phase should be applied to integration testing to ensure consistency across all integrated systems.
Integration testing verifies that different systems and modules work together seamlessly. It helps identify and resolve any issues that arise from system interactions, ensuring that data flows smoothly and processes remain uninterrupted across platforms.
Next Level Testing
Take your testing to the next level—not just by confirming functionality but by pushing boundaries and simulating real-world challenges, including physical constraints and peak season demands. A WMS system is not only physical and transactional but also uniquely built to handle massive volumes of data, making its testing process more intense than many other system implementations. Recognizing this distinction, along with the unique testing considerations already mentioned, is essential for ensuring robust performance and resilience under pressure.
- Consider physical constraints
Physical sizing and constraints (e.g., pallet capacity, location sizes, outbound carton dimensions, and truck dimensional and weight limitations) play a huge role in how a WMS functions. A WMS bridges the gap between the physical world and that of the data within the system, so the way they communicate and interact with each other will have a direct impact on your productivity.
Imagine a warehouse receives six separate orders for the same type of large appliance in one day being shipped in the same outbound truck. Without considering physical constraints, the system might direct workers to pick each appliance individually, which is time-consuming and labor-intensive due to their size and weight. However, if the WMS had a protocol to account for physical constraints, such as bulk picking, it could have directed workers to pick a full pallet of appliances at once. This would streamline the process, saving both time and labor costs. - Consider peak performance
Testing the happy path is only the beginning. Once common exceptions have been tested, it’s important to zero in on more unlikely scenarios to get an idea of how the system will handle them. For example, instead of having 1 person processing an order, test the system to see how it reacts when 80 people are processing multiple orders at the same time. Then, add in some receiving and cycle counting as well.
Volume (aka stress or peak) testing allows users to understand how a system will function at its operational limits. Push the WMS by overloading the system with tasks or users, reducing system resources (like bandwidth), or simulating hardware failures. This is an opportunity to simulate how a system may function during peak season when hundreds of employees are processing orders simultaneously to verify if the system can handle the workload without slowing down or crashing. This is also an opportunity to identify any bottlenecks and performance issues that may not be obvious from previous testing. - Consider post-launch monitoring
Proactively testing post-launch performance ensures the system continues running smoothly under real-world demands. You want to see how it continues to work after scaling, adapting to new demands, and integrating new features. Keep an eye on exception reports to ensure long-term efficiency, and address slowdowns as they arise.
Running tests for the real world ensures the system can handle high workloads and peak demands without crashing. Testing the system under stress identifies bottlenecks and improves overall system efficiency and responsiveness during real-world usage. By testing with physical characteristics in mind, major meltdowns can often be avoided by identifying those problems before go-live.
Key WMS Testing Tips to Ensure System Stability and Performance
WMS testing is an essential phase of any successful implementation. By using these WMS testing tips to evaluate the system across multiple dimensions—system functionality, performance under stress, and integration with other systems—you ensure the WMS is ready to handle real-world challenges. With a well-tested WMS, your warehouse will be better equipped to meet operational demands, increase productivity, and drive long-term success. No matter where you are in your WMS journey, if you’re feeling overwhelmed or in need of guidance, look no further. We have the know-how you need to select, implement, or overhaul a system, simply reach out.