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Success Stories - Habasit

The challenge faced by Habasit is one that affects many manufacturing and distribution businesses worldwide. How can stock be tracked efficiently throughout the production process? One solution is to move from a paper system to an automated system, which is exactly what Habasit wanted to do.

Habasit's reasons for moving away from a paper system are many-fold. Their primary need was to increase efficiency and obtain accurate real-time information about the progress of an order. Habasit were experiencing difficulties in monitoring the progress of stock through the production process, which in turn realised a gap in knowledge in the time taken to finish a product. As each order is bespoke, charging for man hours can be complicated and often inaccurate. An electronic system enables an accurate time frame to be given as the system can monitor the time taken for the product to be finished.

"A major cost saving benefit of the barcoding system has been a reduction in wasted material at the Picking stage. The new system holds all of the available stock sizes and their locations within the warehouse, so that the best fit roll for the job is automatically located." - Simon Hart, Financial Controller at Habasit

Application Overview

The warehouse at Habasit is split into 5 areas of production; Scheduling, Picking, Slitting, Joining and QA (where extra parts are added to the belts). There were 2 major phases to the project at Habasit; organising the stock in the warehouse and then tracking the products through manufacturing. As there had previously been no system, organising the warehouse was a major undertaking as components had to be put away in specific bays and the information had to be recorded into the system. To do this Barcode-IT recommended the Falcon 4420 rugged scanner combined with a mobile printer, so that replacement labels could be printed on-site should amendments need to be made. Cisco 1200 access points were set up at either end of the warehouse to enable the mobile RF terminals to communicate with the system, positioned to give the most cover possible.

Phase 2 required a software program to be developed, which Habasit decided to write in-house, to track goods through the warehouse and show efficiencies in the production process. At each production area a number of computers are equipped with Gryphon D100 CCD scanners and Zebra TLP2844 printers. The initial works document identifying the specifications of each belt is printed as a barcode onto a label in the structuring area. Then at each stage of production the barcoded label is scanned into the system and the information is relayed to the operator. The system asks for the operator details and records the time taken to complete the section, to produce the required data for efficiency monitoring.

"Barcode-IT understood the requirements of the project and helped enormously in assisting with the conceptual planning. We also worked closely together to ensure a smooth implementation." says Simon

How it started

Habasit discovered Barcode-IT via a fact finding search on the Internet. They had a requirement to switch from a paper system in the warehouse to a barcoding system, in order to improve efficiency and cost. Their plan was to write the software for the application in-house and buy in the hardware. A subsequent meeting highlighted Barcode-IT’s ability to provide the hardware for the solution that Habasit wanted to create.

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