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Introduction
In the highly competitive and ever-expanding consumer goods market, a leading ice cream manufacturer in India faced mounting challenges with increasing demand for their products. Operational issues pertaining to Finished Goods (F.G.) Inventory and Dispatch Accuracy were hindering their growth potential. To address these challenges effectively, the company sought a comprehensive solution that would ensure product quality assurance, traceability, and operational efficiency.
Challenges
- COMPETITIVE MARKET
- PERISHABILITY
- DISPATCH ACCURACY
- PRODUCT VARIETY
Solutions
- To overcome these multifaceted challenges, the company turned to Raj Barcode, a trusted provider of AIDC traceability solutions.
The Solutions
- Dispatch Validation: At the dispatch dock, each item was automatically scanned by Fixed Mount Scanners and sensors integrated with Conveyor Line PLC.The system verified that the intended material was loaded onto the truck, stopping the conveyor line in case of discrepancies. Multiple sales orders could be efficiently loaded onto a single truck, following the Last-In-First-Out (LIFO) method.
- Stock Inward: Automatic cold storage inward of stock, with production counts provided by the barcode system, serving as input for production confirmation in SAP.
- Sales Order Integration: Integration with Sales Order Data, allowing for efficient wave picking of materials from cold storage.
- Barcode-Based Sorting: Materials picked from storage were sorted and allocated to the conveyor line using barcode systems.
Results
- Restricted Batch Control
- Adaptability to Schemes
- Minimized Ageing Stock
- Reduced Dispatch Errors
- Enhanced Productivity
System Integrations
- Integration with SAP
- Conveyor Mount Scanners
Solution Highlights
- Production Confirmation in SAP: The system streamlined production confirmation through the barcode system.
- SKU, Batch, and Cold Storage Tracking: Offering a detailed view of stock availability based on SKU, batch, and cold storage locations.
- Operational Accuracy: Ensured overall operational accuracy, reducing costly errors.
- Cost Savings: Reduced invisible costs related to stock ageing and dispatch errors.
- Physical Inventory Count: Simplified and improved the physical inventory count process.
Conclusion
- In conclusion, the implementation of Raj Barcode's traceability solution provided the ice cream manufacturer with a comprehensive, adaptable, and efficient system to address their operational challenges.
- This case study underscores the importance of technology-driven solutions in optimizing operations and ensuring product quality in the food industry.