Automated Data Collection Cuts Costs and Saves Time
Situation
A Utility Cooperative in Nevada was realizing inventory errors that were costing the Cooperative dollars and their employees time.
They recognized the need to automate the flow of data within its warehouse facility. The decision was made to pursue an automation project to realize many efficiencies offered by an automated data collection system including reduced errors, increased accuracy, cost savings and employee time savings.
Solution
In order to implement such a system, the Cooperative knew there were several hurdles to clear. Namely, how to interface with its Host Software, iVUE and how to justify the costs for the RF backbone and newer generation terminals. In addition, consideration had to be given to "link" the systems with an RF utility program and how to integrate a database that could flawlessly communicate with the host computer’s history file.
At this juncture, the Cooperative contacted Integrity Data Solutions, Inc. Members of the ID Solutions team had been part of the creation of the batch system and had intimate knowledge of the warehouse operation at the Coop. Contact was made during the 1st Quarter, 2000 and plans were made to develop the complete specifications of the proposed RF system. ID Solutions, Inc. detailed the system specifications in a Systems Requirements Plan Document (“SRP”) and presented the proposal implement MOBILETrak WMS to the Coop.
MOBILETrak WMS provides the following critical improvements in efficiencies over the Cooperative’s previous batch system:
Real-Time, instantaneous updating of collected data to the host computer.
Major reductions in manual and/or labor intensive operations resulting in significant time and cost savings. For example, with MOBILETrak, a “Warehouse Move” transaction simply involves a series of scans of items and location tags. Prior to MobileTrak, the process was labor intensive and involved warehouse personnel moving throughout the warehouse. Another example would be the introduction of 3 “Pick” options: (1) “Unguided” for personnel with an intimate knowledge of the warehouse layout, (2) “Guided (by item)” directing warehouse personnel through the warehouse in item order or (3) “Guided (by location)” directing warehouse personnel through the warehouse in location order.
Introduction of “Batch Picking” allowing a single scan to capture data for multiple items of components in a Bill of Materials.
Introduction of a single “Log In” function in the Main Menu design allowing users to log into the system a single time with access to each individual module.
Introduction of Query-based Reporting capabilities allowing for more powerful and flexible reporting features. Users are able to design meaningful reports based on database queries through the use of macro commands.
Increased system security. Warehouse personnel can collect data, but are prevented from manipulating or altering data, or compromising the integrity of the data transactions. Security levels can be assigned specific to the user profile.
Introduction of a “Tool Crib” module allowing for check-in, check-out features for production assets such as tools and supplies, etc.
Comprehensive “Error-Checking”. The system has a variety of intuitive checks built into the software design that prevents the transmission of erroneous data. For example, the MOBILETrak WMS does not allow “picked” quantities to reduce inventory quantities below a zero quantity. Errors are detected and prevented in a real time environment, preventing erroneous data from ever entering the database.
Comprehensive “Validation”. Similar to error checking described above, MOBILETrak has been designed to provide critical validation features such as validating new warehouse locations in the Receiving and Put Away modules.
Results
The Cooperative had a shrinkage/Loss of over $100,000 in the 12 months prior to installing MOBILETrak WMS. The following 12 months evaporated to $5,000 in loss. MOBILETrak paid itself off several times over the 12 month span.
