Objective:

The client is set to enhance its existing Warehouse Management System (WMS) by implementing RFID technology at its Fabric Warehouse. This transformation aims to improve inventory accuracy, real-time visibility, and operational efficiency while supporting the company’s broader strategy of technological innovation and supply chain excellence.

Strategic Goals:

• Improve Inventory Accuracy
  Real-time tracking of fabric rolls and cut pieces to eliminate manual errors and stock mismatches.
• Enhance Operational Efficiency
  Automated receiving, picking, and dispatching processes to reduce manual dependency and speed up workflows.
• Increase Visibility
  Centralized control and zone-level tracking within the warehouse for faster decision-making.
• Reduce Operational Costs
  Minimize labor efforts, reduce time spent in verification, and optimize roll usage across orders.

Current Pain Points:

Despite using barcodes and an advanced WMS, several operational challenges persist:

1. Manual Roll Identification & Updates
   • Reliance on manual records and delayed ERP updates.
   • Time-consuming physical search despite barcode tagging.
2. Lack of Real-Time Data on Cut Rolls
   • Physical verification required for cut quantity.
   • Delays and approximations impacting order fulfillment.
3. Inaccurate Roll Location Tracking
   • Misplaced rolls across adjacent bins or incorrect zones.
   • Marked zones not strictly adhered to.
4. Stock Visibility & Utilization Issues
   • Difficulty in identifying balance meters.
   • Multiple picks of the same SKU due to poor visibility of available stock.
5. Operational Bottlenecks
   • Report generation delays.
   • Over 100,000 rolls manually accounted for.
   • Time-consuming identification of rolls by specification/quantity.

Purpose of the RFID Project:

1. Fast & Accurate Cut Roll Identification
   • Use RFID-enabled light and sound indicators to assist in quick, person-independent identification during picking.
2. Zone-Wise Roll Tracking
   • Real-time tracking of rolls across various zones to enable seamless flow and easy traceability.
3. Optimized Roll Utilization Across Orders
   • Enable the same roll to be used for multiple orders intelligently, reducing redundant picks and increasing picking efficiency.
4. Data-Driven Productivity Monitoring (Phase II)
   • Enable tracking and analysis of productivity at individual resource and infrastructure (e.g., machine, table) level for future optimization.

Implementation Focus:

• Seamless RFID integration with existing WMS and ERP.
• Minimal disruption to ongoing operations during implementation.
• Scalability for future automation and analytics capabilities.