How Godrej Transformed Warehouse Rack Safety and Scaled Nationwide Audits with Pro-Inspector?

Founded in 1897, the Godrej Enterprises Group has built a legacy of innovation in Indian industry—from designing springless locks to developing critical components for India’s space programs. Today, Godrej plays a pivotal role in multiple sectors, including clean energy, green construction, aerospace, and smart intralogistics. As a leading manufacturer and supplier of warehouse racking systems for major e-commerce clients like Amazon and Flipkart, maintaining operational integrity and safety across warehouse environments is non-negotiable.

In 2022, Godrej partnered with Pro-Inspector to digitize its rack inspection and audit process. The goal was to eliminate manual workflows, improve compliance visibility, and standardize operations across a growing footprint of warehouses—each typically spanning over 1,500 sq. ft. Pro-Inspector’s inspection software and compliance management tools provided the right platform to drive this transformation.

Challenges

Godrej’s traditional inspection process for warehouse racks was built around fragmented, manual workflows. This created multiple operational pain points:

Lack of real-time visibility into inspection results across geographically distributed warehouses
Manual entry and inconsistent evidence gathering led to errors in reporting and risk prioritization
Difficulty generating and sharing a detailed Bill of Materials (BOM) for damaged rack parts
No structured system to classify risk severity or enforce corrective actions
Delays in scheduling, conducting, and reviewing audits due to non-centralized systems

Given the scale of operations and growing client expectations, Godrej needed a robust, mobile-first solution to streamline inspections and ensure compliance at every level.

Solution

To address these challenges, Godrej implemented Pro-Inspector, a comprehensive inspection and audit app designed for modern, field-based operations. The rollout included:

Layout-Driven Audits: Upload floor-wise layout files to inspect large warehouses with pinpoint accuracy.
Visual Evidence Capture: Attach geo-tagged photos & videos for every rack defect.
Criticality Color Coding: Classify findings using Red, Amber, Green (RAG) indicators to denote risk levels.
BOM Template Integration: Generate a Bill of Materials for replacement parts directly from audit findings.
Schedule & Assign Audits: Assign tasks, attach relevant files, and conduct audits via mobile using the Pro-Inspector app.
Custom Audit Reports: Generate detailed audit reports with risk categorization and compliance scores.
One-click Approval Workflow: Review, approve, and instantly share reports and BOMs with clients.

The platform also allowed custom rule enforcement during inspection, such as requiring racks to be empty (where possible) and highlighting missing fasteners, rust formation, and out-of-plumb uprights.

Risk Category System

A core part of the Pro-Inspector-enabled audits is the Risk Category System, which classifies rack component issues based on severity to guide timely action:

Green Level – Surveillance Only

This category includes components that are currently safe and serviceable. No immediate action is required, but these areas should be recorded and re-assessed during the next scheduled inspection. If left unchecked, they could evolve into more serious issues.

Amber Risk – Hazardous Damage Requiring Prompt Action

Amber-level damage signals structural wear or impact that demands replacement of the damaged component. While it does not warrant immediate off-loading, it requires urgent attention. Once unloading occurs, reloading is prohibited until full repairs are completed and safety is re-certified. If unresolved within four weeks, Amber issues are escalated to Red.

Red Risk – Critical Damage Requiring Immediate Action

This is the highest risk level. Components with Red risk must be immediately off-loaded and isolated. Repairs or replacements must be conducted before resuming any operations. Failure to act can pose severe safety risks to both personnel and inventory.

This classification framework ensures a systematic, safety-first approach that prioritizes action based on severity, reducing potential liability and increasing transparency during client communication.

Business Impact

The shift to Pro-Inspector resulted in tangible improvements across key business areas, beyond just operational enhancements. Godrej experienced a 25-30% reduction in man-hours per audit, allowing its field teams to handle a greater number of inspections without additional hiring. This efficiency directly translated into faster audit-to-BOM cycles, cutting delays in client communication and enabling quicker turnaround on replacement orders.

With real-time dashboards and compliance scoring, Godrej improved its regulatory preparedness and internal audit targets significantly reducing the risk of non-compliance penalties. Moreover, the instant availability of audit findings and visual evidence helped enhance trust and transparency with e-commerce clients. As a result, Godrej strengthened its service-level agreements and long-term retention with key partners like Amazon and Flipkart.

The standardized digital process also positioned Godrej for scalable operations across 100+ warehouses nationwide. Pro-Inspector empowered the organization to deliver consistent, repeatable inspections whether performed by internal teams or third-party contractors. Leadership gained access to inspection trends and risk pattern analytics, which informed strategic decisions in both design improvements and preventive maintenance.

From a financial perspective, the automation of BOM creation, report generation, and communication workflows helped Godrej save an estimated ₹20–30 lakhs in annual operational costs. Furthermore, by offering Pro-Inspector-driven audits as a value-added service, Godrej was able to differentiate itself from competitors and reinforce its position as a tech-enabled intralogistics partner.

Conclusion
The integration of Pro-Inspector’s software for inspection helped Godrej transition from manual, fragmented rack audits to a digital-first, scalable compliance solution. By digitizing field audits, automating risk categorization, and centralizing communication, Godrej achieved faster resolution cycles, stronger client relationships, and measurable operational savings.

Today, Godrej continues to lead with innovation, not just in manufacturing, but in how it delivers trust, safety, and efficiency across India’s warehousing landscape. Pro-Inspector remains a critical partner in enabling that transformation – powering daily audits, enhancing compliance, and ensuring future-ready performance.

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