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Success Stories - Trackside FulfilmentOver recent years our customer has seen a significant increase in production at their manufacturing plant, due to the addition of a new prestige motor car range. Previously producing just 1200 of these bespoke cars per annum, production figures were projected to rise to 10,000 per year, added to by the introduction of the new line in 2006.
As a result of this production increase, staffing figures were forecasted to increase from 120 to 800. Our customer made the decision that an automated picking and tracking system would be a great cost saving solution, as staff at the site would only need to be increased to 300.
Our customer has seen a variety of benefits from implementing the automated system. The most noticeable is traceability. Parts can be tracked easily from offsite to onsite stores and through to track-side, making the supply chain process completely visible and providing real-time information to users. Staffing efficiencies can also be seen, resulting in improved monitoring of productivity and ease in allocating staff.
"Initially, the RF system has solely been introduced into the production process for this specific range, but after the success of the project there are now plans to implement a system into our prototype storage facility and going forward, other existing production lines." says their Logistics Manager
Application Overview
The automated system allows operators to track products from picking in the offsite store, through transportation and finally to offloading onsite, in real-time.
The process begins in the offsite storage facility. Our customer required truck mounted mobile computers in the offsite store to assist workers with putting away and picking parts. The Trux X5 terminals are fixed to 14 forklift trucks and provide operators with full access to the SAP system at their fingertips. Trux terminals were selected due to their robustness and large screen, which enables workers to easily view their full pick list.
Once transported to the onsite store, parts can then be put away, using the Falcon terminals, in specific bin locations in the stores. When parts are required on the production line, items are picked from the onsite stores and transported to specific track-side locations, all the time being scanned in and out by the Falcon terminals. Conversely the system allows information to be sent to the offs
"Barcode-IT were not afraid to show us new and innovative technology, as other firms seemed to be. They listened to all of our ideas but were equally not frightened to add in their own suggestions and ideas to improve the system" he continues, "Most importantly, Barcode-IT were able to work to our very tight time scales and even helped to move the project along faster themselves at some stages!"
How it startedDash Computer Products, the parent company of Barcode-IT, have had a relationship with this company since 2000. When it came to finding a partner to supply the hardware for their project, this previous relationship gave them the confidence to trust in the solution Barcode-IT was proposing.
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Our customer turned to Barcode-IT to provide the right solution for their project. They were already running SAP R3 and needed to link hardware to the main SAP system. Before the automated system was put in, the site was like many manufacturing environments and picking stock was an arduous and time consuming process carried out manually by workers. To reduce picking errors and increase traceability, our customer implemented around 14 
ite store to order parts that are needed by production, simply by scanning in the part number and stating the quantity required. The process eliminates complicated spreadsheets for ordering and many potential errors within the ordering procedure.
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