One of the largest tile manufacturers in Asia manages 60,000 square meters of storage space and 70,000 pallets with more than 50 forklifts. Every week, about 120,000 movements of goods are carried out.
Task/Objective: Large quantities produced in stock with a large number of similar items as well as confusing and spacious warehouses lead to high search times. Batch delivery of the same products in compliance with FIFO is very important. The goal is a defect-free, reliable solution for controlling goods under extreme demands on robustness and flexibility that withstands tropical environmental conditions.Impeccable loading and fast handling of the trucks as well as precise control and coordination of the numerous transport orders in the goods-to-man-controlled picking area are essential. Paper-based storage processes and the previously inadequate control should run reliably. In particular, inventory uncertainty, lack of transparency of warehouse processes, long search times and incorrect batch-related delivery are critical.
Solution: Track+Race® was installed to control the flow of material in production, warehouses and order picking zones, making it possible to precisely control and track goods and forklift movements. Via interfaces to the ERP and warehouse management system, Track+Race® receives the transport requirements and confirms them after execution. All processes in the warehouse are automatically and paperless controlled and the generated data is saved.
Result: Track+Race® has synchronized information and material flow, optimizing the communication process in the warehouse. With precise knowledge of the condition and location of the goods and forklifts, it enables controlled, error-free and transparent processes in warehouse and shipping. Search times were eliminated, paper-based processes abolished and truck loading significantly accelerated. The stored data is evaluated, providing management with up-to-date insight into inventory metrics and productivity as well as all the data needed to control daily operations.