Codeway equipped the FLTs with WiFi terminals for SAP and scanners for drivers to read item barcodes. Image: Hyster-Yale, Bolzoni

High volume distribution

This distributor of white goods and home appliances serves the UK from a 250,000 sq ft warehouse. There are unloading/loading bays for most consignments but some consignments are handled in a covered area along one side of the building.

Ten years ago the company decided to move to a SAP ERP system. It was time to replace their ageing WiFi network and mobile terminals, and introduce barcode scanning. A key requirement was to eliminate illicit movements of stock from the site.

A SAP consultant introduced the company to Codeway.

The original system

The plan

Codeway was responsible for

1. Do an immediate RF site survey to replace the existing indoor network and extend WiFi coverage to the outside covered area.
2. Provide 20 vehicle computers with rugged Bluetooth barcode scanners for the fork lift trucks.
3. Provide 4 mobile terminals for supervisors to maintain perpetual inventory.
4. Provide 4 mobile terminals with portable 4 inch label printers for small item and parts picking and packing.
5. Test the terminals for SAP transactions.

Implementation

The company's site manager, their IT manager and the Codeway team completed the project within a four month schedule. We had to sort out some unforeseeable installation problems with the terminal manufacturer and the fork lift truck suppliers.

Inconsistent barcodes from different plants

Inconsistencies between the barcodes from several manufacturing plants round the world were the major issue. These looked like equipment failures to the drivers but the solution was to configure the scanners and the terminals to deal with them. The IT manager and a Codeway software engineer found no problems during the SAP tests.

Technical support

During their lifetime Codeway provided the technical support to diagnose and resolve problems with the terminals. Most were due to operating software updates and unexplained changes in network switch settings. We also advised on sitching terminals to new fork lift trucks.

End of life

After eight years the company decided to replace the terminals and enhance the network. Repair bills were increasing and the manufacturer had declared 'end of life' for the terminals.

The new system

The company came to Codeway for a refresh.

There was a similar plan:

1. Improve network coverage of a few weak spots in the warehouse and the covered area.
2. Install 15 vehicle terminals with rugged Bluetooth scanners.
3. Provide 2 mobile terminals for supervisors to maintain perpetual inventory.
4. Provide 4 mobile terminals with portable label printers for small item and parts picking.

Codeway installed the new terminals on the fork lift trucks, resolving a minor cabling issue with manufacturer within 24 hours.

Results

SAP implementation

The system enabled the company to introduce SAP to the warehouse with no major hitch.

Productivity

Realtime operation, with barcode scanning and an effective WiFi network, has helped to increase productivity at the distribution centre. Based on the number of terminals and sales values, productivity is up:

• 15% for fork lift movements.
• 50% for stock supervision.

Stock control

The figures show stock is far easier to control with barcodes. Shrinkage has been greatly reduced if not eliminated.