A leading film manufacturing and logistics company needed to automate inventory tracking, optimize warehouse operations, and monitor the movement of film rolls across its facility in real time. Rolls were tracked manually, finding a specific roll could take up to an hour, and dispatches left the plant without any systematic validation.
POXO implemented an RFID-based Warehouse Management & Location Tracking System with a distinctive twist: RFID readers mounted directly on the overhead cranes that move the rolls, continuously scanning floor-mounted location tags. The result — 100% real-time inventory tracking, warehouse operations 70% faster, and 99% dispatch accuracy.
Business Challenges
- Manual Inventory Tracking: Stock updates were error-prone and always behind reality.
- No Real-Time Location: There was no automated way to know a specific roll’s exact position — searching took 30–60 minutes per item.
- Inefficient Dispatch Management: Outgoing goods were not validated, leading to discrepancies and losses.
- Application Silos: Different applications operated in isolation with no real-time data synchronization.
Solution Overview
POXO delivered a complete warehouse management platform built from purpose-specific applications, all synchronized in real time:
- Desktop Application — admin control, user management, and reporting.
- Tablet Application — picklist and packlist information displayed at designated work areas.
- Smart TV Application — a live warehouse operations dashboard visible on the floor.
- Handheld Terminal (HHT) Application — real-time inventory location mapping on the move.
- Crane-Mounted RFID Tracking — readers on overhead cranes scanning floor location tags to automate roll movement tracking.
- 24×7 Background Services — constantly updating the real-time location of every roll.
- Dispatch Monitoring System — RFID validation of every outgoing dispatch.
- SAP Integration — location and dispatch data exchanged with the client’s existing SAP system.
Implementation Details
1. RFID-Based Location Tracking from the Crane
Fixed RFID readers were installed on the overhead cranes that physically move the rolls. As a crane travels, it continuously scans RFID location tags installed on the floor, associating each roll movement with an exact position. Every put-away and relocation updates the system automatically, every movement is logged for audit history, and any roll can be located instantly.
Impact: 100% elimination of manual tracking, with accurate real-time mapping of every roll in the facility.
2. Warehouse Operations Automation
The WMS became the central platform for daily operations: real-time inventory updates the moment an item is placed or moved, automatic put-away location assignment, item-level verification before any movement or dispatch, and detailed reports on stock levels, movements, and usage trends.
Impact: Warehouse operations over 70% faster, fewer inventory discrepancies, and better space utilization.
3. RFID-Enabled Dispatch Verification
Every outgoing item is verified by scanning its RFID tag at dispatch. Unauthorized or incorrectly picked items trigger instant alerts, and a digital record of every dispatched consignment is maintained — visible live on the loading-gate dashboard.
Impact: 99% dispatch validation accuracy and zero unauthorized dispatches.
4. Real-Time HHT Mapping & Mobile Integration
The Android-based handheld terminal application gives floor staff mobile access to the WMS — stock verification anywhere in the plant, on-the-spot scanning during audits, and seamless sync with the central system.
Impact: Workforce mobility improved efficiency by 50%, with audits completed in a fraction of the time.
Technology Stack & System Architecture
Built on a client-server architecture with local data storage for security and high availability:
- Desktop Application: .NET (C#) Framework
- Mobile (HHT) Application: Android
- Database: MS SQL Server, hosted locally for speed and security
- Background Services: 24×7 real-time tracking updates
- Integration APIs: Real-time data sharing across all applications and SAP
Business Outcomes & ROI
| Metric | Before | After |
|---|---|---|
| Inventory Search Time | 30–60 minutes per item | Instant RFID scan |
| Item Misplacement | Common | Near zero |
| Dispatch Errors | Frequent | 99% accuracy |
| Warehouse Productivity | Manual, slow processes | 70% faster |
| Audit & Reporting Time | Weeks | Instant reports |
Key achievements: 100% real-time inventory tracking · 70% reduction in warehouse processing time · 99% dispatch accuracy · zero item misplacement.
Conclusion & Future Enhancements
The RFID-based Warehouse Management & Location Tracking System transformed the client’s inventory operations — automated tracking with real-time updates, efficient stock movement and dispatch management, and a sharp reduction in labour-intensive processes.
The roadmap extends further: AI-powered predictive analytics for demand and stock forecasting, cloud-based integration for remote monitoring, and IoT-enabled smart alerts for movement and dispatch exceptions.
As an ISO 9001:2015 certified provider of end-to-end RFID and IoT automation, POXO designs warehouse systems around how each plant actually operates — crane-mounted readers included. Explore our warehouse management solution or talk to our team about your facility.