Rolling out Ply in your warehouse? Whether you're just getting started or managing multiple locations and trucks, this guide walks you through everything you need to set up your materials, bins, and barcodes, based on a real implementation in a $30M HVAC/plumbing operation.
š§ What is PWI?
PWI stands for Ply Warehouse Implementation - a structured, hands-on approach to getting your warehouse running with Ply. From labeling bins to uploading materials, this guide helps you turn a physical space into a fully traceable digital inventory without disrupting day-to-day operations.
š„ Video tutorial:
š„ Watch It in Action:
Want to see the full implementation walkthrough, live from the field? Check out the recording below:
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š§° What Youāll Need
Before jumping in, hereās a quick checklist:
Ply mobile app
Brother PT-910 label printer with 24mm or 36mm tape
Ply count cards (or printed versions with material info and barcodes)
A pen (still essential!)
A clean workspace and organized bins
(Optional) A counting scale (from Uline or similar)
(Optional) Temp labor for high-volume projects
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šļø How to Organize Your Warehouse
Structure your storage with a four-part location format:
Aisles (e.g., A1, A2)
Bays within each aisle
Levels (shelving height)
Bins (individual compartments)
š Example: Aisle 1 / Bay 1 / Level 2 / Bin 3
Clear labeling upfront saves hours later on.
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š Step-by-Step Implementation Workflow
1. Count What You Have
Choose a small section to start. For each bin:
Count the items
Write the name, quantity, and location on a temp tag (sticky note or paper slip).
2. Add It to Ply
Scan a barcode (existing or new).
If itās not in Ply, create a new material.
Fill in optional fields like unit, image, or description.
š” You can link multiple barcodes to a single item.
3. Print Your Labels
Use the Ply app to create a list of materials.
Select Layout 3 + Landscape.
Set font size to 120 for high visibility.
Print and apply labels in order.
4. Label + QA
Match the printed label with the temp tag on the bin.
Stick the label on the corresponding bin.
Scan it again to verify itās recognized in Ply.
š Keep Operations Moving
Implement in chunksāa bay, an aisle, or by item category. You donāt need to shut down operations:
In-Progress Tracking: Use sticky notes/temp tags to mark bins currently being processed.
Live Inventory Shifts: If stock changes mid-process, cross out the written number and update it.
Speed Target: Aim for ~2ā3 minutes per item (counting, entry, and labeling).
š Updating Inventory in Ply
Use the scanner to update quantities (e.g. after receiving or pulling stock)
Transfer materials between locations or warehouses from the app
All movements are recorded and show up in Ply reports
š¦ Setting Up Vendor Managed Inventory (VMI)
Set up a supplier-managed section inside your warehouse:
Create a separate "Warehouse" location in Ply for your VMI area.
Allow suppliers to scan and build orders directly in the app.
Retain full inventory visibility without holding materials on your balance sheet.
Proven Success: Successfully implemented with partners like Ferguson for truck stock resets and on-demand deliveries
ā” Pro Tips Tips That Save Time
Multi-Barcode Focus: Toggle scan mode manually when several barcodes are close together.
Low-Light Areas: Use your phone flashlight directly through the app scanner.
Batch Printing: Build item lists first, then print all labels at once to streamline application.
Zero-Waste Printing: Take advantage of Plyās seamless batch-printing integration with the Brother PT-P910BT.
š§āš§ Scaling Up & Cycle Counts
Temp Labor: Hire local workers via platforms like Jobble or Instawork to handle physical counting and writing temp tags.
Bulk Data Entry: Photo-document filled temp tags, use OCR/AI extraction (e.g., ChatGPT) to convert the data into a CSV, and upload to Ply in bulk.
Quarterly Cycle Counts: Reuse this exact 4-step framework for regular cycle counts. Simply swap out permanent bin labels for temporary sticky notes to track progress during the audit.