wms-testing-patterns

# WMS Testing Patterns <default_to_action> When testing Warehouse Management Systems: 1. VALIDATE inventory accuracy (receipt, putaway, cycle count, adjustments) 2. TEST pick/pack/ship workflows end-to-end (wave release -> shipment confirm) 3. VERIFY EDI message processing (856 ASN, 940 Order, 945 Confirmation, 943/944 Stock) 4. ASSERT RF/barcode scanning flows (scan -> validate -> update -> confirm) 5. EXERCISE allocation and replenishment logic (FIFO, FEFO, lot control) 6. TEST WMS-ERP integration (inventory sync, order status, goods receipt) 7. VALIDATE wave management (wave planning, release, short-pick handling) **Quick Pattern Selection:** - Inventory discrepancies -> Cycle count and adjustment tests - Order fulfillment issues -> Pick/pack/ship workflow tests - EDI failures -> Message format and acknowledgment tests - Scanning problems -> RF device simulation tests - Allocation errors -> Lot control and FIFO/FEFO tests - Integration gaps -> WMS-ERP sync boundary tests **Critical Success Factors:** - WMS accuracy directly impacts customer experience and financial reporting - Always test both normal and exception flows (short picks, damaged goods, returns) - EDI testing must cover both syntax validation AND business rule validation </default_to_action> ## Quick Reference Card ### When to Use - Testing WMS platforms (Blue Yonder/JDA, Manhattan Associates, SAP EWM, Oracle WMS) - Validating inventory transaction accuracy (receipts, picks, adjustments) - Testing EDI document exchange (X12 856/940/945/943/944, EDIFACT DESADV/ORDERS) - Verifying RF/mobile scanning workflows - Testing wave management and allocation logic - Validating WMS-to-ERP integration (SAP MM/WM, Oracle) ### Testing Levels | Level | Purpose | Dependencies | Speed | |-------|---------|--------------|-------| | Unit Logic | Allocation/replenishment rules | None | Fast | | API Contract | WMS REST/SOAP endpoint contracts | API stubs | Fast | | EDI Validation | Document syntax + business rules | EDI parser | Medium | | Integration | WMS-ERP inventory sync | Full stack | Slower | | E2E Workflow | Complete order fulfillment cycle | WMS + ERP + TMS | Slow | ### Critical Test Scenarios | Scenario | Must Test | Example | |----------|----------|---------| | Receiving | Inbound accuracy | PO receipt with over/under delivery tolerance | | Putaway | Location assignment | Directed putaway by product attributes | | Picking | Wave/batch pick | Multi-order wave with priority allocation | | Packing | Pack verification | Cartonization and weight/dim validation | | Shipping | Carrier assignment | Rate shopping and label generation | | Cycle Count | Inventory accuracy | Blind count vs. guided count reconciliation | | Returns | Reverse logistics | RMA receipt, inspection, disposition | | EDI 856 | ASN generation | Ship-confirm triggers correct ASN to customer | | EDI 940 | Warehouse order | Inbound order creates correct work orders | | Short Pick | Exception handling | Partial allocation with backorder creation | ### Tools - **WMS Platforms**: Blue Yonder WMS, Manhattan WMOS, SAP EWM, Oracle WMS Cloud - **EDI Testing**: Bots EDI, SPS Commerce Test, Cleo Clarify - **RF Simulation**: Custom RF emulators, Zebra SDK test harnesses - **Integration**: SAP PI/PO, MuleSoft, Dell Boomi - **Monitoring**: Splunk, WMS dashboards, EDI tracking portals ### Agent Coordination - `qe-middleware-validator`: WMS-ERP integration flows and message transformation validation - `qe-contract-validator`: EDI document contracts and WMS API contracts - `qe-sap-idoc-tester`: WMS-SAP IDoc validation (WMMBID01, SHPCON) - `qe-odata-contract-tester`: SAP EWM OData service testing --- ## Inventory Transaction Testing ### Receipt and Putaway ```javascript describe('Inbound Receipt - PO with Lot Control', () => { it('receives goods against PO with lot tracking', async () => { const receipt = await wms.receive({ po: 'PO-4500001234', item: 'MAT-100', quantity: 100, lot: 'LOT-2026-001', expiryDate: '2027-06-30', uom: 'EA' }); expect(receipt.status).toBe('RECEIVED'); expect(receipt.quantityReceived).toBe(100); expect(receipt.lot).toBe('LOT-2026-001'); // Verify putaway task was created const putawayTask = await wms.getTask(receipt.putawayTaskId); expect(putawayTask.type).toBe('DIRECTED_PUTAWAY'); expect(putawayTask.suggestedLocation).toMatch(/^BIN-/); }); it('rejects over-receipt beyond tolerance', async () => { // PO line is for 100 EA, tolerance is 10% const result = await wms.receive({ po: 'PO-4500001234', item: 'MAT-100', quantity: 115, // 15% over, exceeds 10% tolerance lot: 'LOT-2026-002' }); expect(result.status).toBe('REJECTED'); expect(result.reason).toContain('Over-receipt tolerance exceeded'); expect(result.maxAllowed).toBe(110); }); it('accepts under-receipt and creates remaining open quantity', async () => { const result = await wms.receive({ po: 'PO-4500001234', item: 'MAT-100', quantity: 80, lot: 'LOT-2026-003' }); expect(result.status).toBe('PARTIAL_RECEIPT'); expect(result.quantityReceived).toBe(80); expect(result.remainingOpen).toBe(20); }); }); describe('Directed Putaway', () => { it('assigns location based on product attributes', async () => { // Hazmat product should go to hazmat zone const putaway = await wms.executePutaway({ item: 'MAT-HAZ-001', attributes: { hazmat: true, temperature: 'ambient' }, quantity: 50, lot: 'LOT-HAZ-001' }); expect(putaway.location).toMatch(/^HAZ-/); // Hazmat zone prefix expect(putaway.status).toBe('PUTAWAY_COMPLETE'); }); it('falls back to overflow when primary zone is full', async () => { // Fill the primary zone first await wms.fillZone('ZONE-A', 100); // 100% capacity const putaway = await wms.executePutaway({ item: 'MAT-200', quantity: 10, preferredZone: 'ZONE-A' }); expect(putaway.location).toMatch(/^OVF-/); // Overflow zone expect(putaway.overflowReason).toBe('PRIMARY_ZONE_FULL'); }); }); ``` ### Cycle Count and Adjustments ```javascript describe('Cycle Count - Blind Count', () => { it('auto-approves variance within threshold', async () => { // System shows 100 EA, physical count is 98 const count = await wms.submitCycleCount({ location: 'BIN-A-01-01', item: 'MAT-100', countedQuantity: 98, countType: 'BLIND', // Counter does not see system quantity varianceThreshold: 5 // percent }); expect(count.systemQuantity).toBe(100); expect(count.variance).toBe(-2); expect(count.variancePercent).toBeCloseTo(2.0); expect(count.autoApproved).toBe(true); expect(count.adjustmentPosted).toBe(true); }); it('requires supervisor approval when variance exceeds threshold', async () => { const count = await wms.submitCycleCount({ location: 'BIN-A-01-02', item: 'MAT-200', countedQuantity: 80, countType: 'BLIND', varianceThreshold: 5 // 20% variance exceeds 5% threshold }); expect(count.variancePercent).toBeCloseTo(20.0); expect(count.autoApproved).toBe(false); expect(count.adjustmentPosted).toBe(false); expect(count.status).toBe('PENDING_SUPERVISOR_APPROVAL'); }); it('triggers recount when variance is critical', async () => { const count = await wms.submitCycleCount({ location: 'BIN-A-01-03', item: 'MAT-300', countedQuantity: 0, // System shows 50 countType: 'BLIND', varianceThreshold: 5, criticalThreshold: 50 }); expect(count.variancePercent).toBe(100); expect(count.status).toBe('RECOUNT_REQUIRED'); expect(count.recountAssigned).toBe(true); expect(count.recountAssignee).not.toBe(count.originalCounter); }); }); ``` --- ## Pick/Pack/Ship Workflow Testing ### Wave Management ```javascript describe('Wave Planning and Release', () => { it('creates wave from eligible orders with batch-pick strategy', async () => { // Create 5 orders for wave planning const orders = await Promise.all( Array.from({ length: 5 }, (_, i) => wms.createOrder({ orderId: `SO-100${i}`, lines: [ { item: 'MAT-100', qty: 10 }, { item: 'MAT-200', qty: 5 } ], priority: i === 0 ? 'RUSH' : 'STANDARD', shipBy: '2026-02-05' })) ); const wave = await wms.planWave({ strategy: 'BATCH_PICK', maxOrders: 10, cutoffTime: '2026-02-05T14:00:00Z' }); expect(wave.orderCount).toBe(5); expect(wave.pickTasks).toBeGreaterThan(0); expect(wave.status).toBe('PLANNED'); // Rush order should be first in pick sequence const firstTask = wave.pickTasks[0]; expect(firstTask.orderId).toBe('SO-1000'); expect(firstTask.priority).toBe('RUSH'); }); it('handles short-pick by creating backorder', async () => { // Only 5 EA available, order needs 10 await wms.setInventory('BIN-B-01-01', 'MAT-500', 5); const order = await wms.createOrder({ orderId: 'SO-SHORT', lines: [{ item: 'MAT-500', qty: 10 }] }); const wave = await wms.planWave({ strategy: 'SINGLE_ORDER' }); await wms.releaseWave(wave.id); // Attempt to pick const pickResult = await wms.confirmPick({ taskId: wave.pickTasks[0].id, pickedQty: 5 // Only 5 available }); expect(pickResult.status).toBe('SHORT_PICK'); expect(pickResult.pickedQuantity).toBe(5); expect(pickResult.shortQuantity).toBe(5); expect(pickResult.backorderCreated).toBe(true); expect(pickResult.backorderId).toBeDefined(); }); }); ``` ### Allocation Logic ```javascript describe('FIFO Allocation', () => { it('allocates oldest lot first', async () => { // Set up two lots with different receipt dates await wms.receiveInventory('MAT-FIFO', 50, { lot: 'LOT-OLD', receiptDate: '2026-01-01' }); await wms.receiveInventory('MAT-FIFO', 50, { lot: 'LOT-NEW', receiptDate: '2026-02-01' }); const allocation = await wms.allocate({ item: 'MAT-FIFO', quantity: 30, method: 'FIFO' }); expect(allocation.allocatedLot).toBe('LOT-OLD'); expect(allocation.quantity).toBe(30); }); it('splits allocation across lots when oldest is insufficient', async () => { await wms.receiveInventory('MAT-SPLIT', 20, { lot: 'LOT-A', receiptDate: '2026-01-01' }); await wms.receiveInventory('MAT-SPLIT', 50, { lot: 'LOT-B', receiptDate: '2026-01-15' }); const allocation = await wms.allocate({ item: 'MAT-SPLIT', quantity: 40, method: 'FIFO' }); expect(allocation.splits).toHaveLength(2); expect(allocation.splits[0]).toEqual({ lot: 'LOT-A', quantity: 20 }); expect(allocation.splits[1]).toEqual({ lot: 'LOT-B', quantity: 20 }); }); }); describe('FEFO Allocation (First Expired, First Out)', () => { it('allocates lot with earliest expiry first', async () => { await wms.receiveInventory('MAT-FEFO', 50, { lot: 'LOT-EXP-LATE', expiry: '2027-12-31' }); await wms.receiveInventory('MAT-FEFO', 50, { lot: 'LOT-EXP-SOON', expiry: '2026-06-30' }); const allocation = await wms.allocate({ item: 'MAT-FEFO', quantity: 30, method: 'FEFO' }); expect(allocation.allocatedLot).toBe('LOT-EXP-SOON'); }); it('excludes expired lots from allocation', async () => {