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Steel Manufacturing

Cloud-based Store Inventory Traceability For A Leading Steel Manufacturer

Client Profile

One of the top integrated steel producers in India, operating at scale with a need for real-time, accurate inventory traceability integrated with SAP.

100% traceability from GRN to consumption achieved via SAP-integrated barcode tracking.

Put-away and pick times reduced significantly through guided bin-level scanning.

Zero manual errors in receiving, identification, and issuance due to end-to-end automation.

The Challenge
The Solution
The Results
  • The client faced challenges managing store inventory, including inefficiencies in manual material tracking, inaccurate stock updates, and a lack of real-time visibility from goods receipt to consumption.
  • Warehouse users struggled with ineffective put-away processes, repetitive data entry, and a disconnect between SAP and on-ground operations, slowing down procurement and production readiness.
  • No automation existed to assist pickers with FIFO-based picking or to enforce traceability from the GRN to consumption lifecycle.

DDAPL delivered a cloud-based traceability solution powered by barcode technology and real-time SAP integration, built for seamless material flow control. Key features included:

  1. SAP Integration via APIGEE Security Layer
    • Secure API layer enabled live data exchange for GRN, Material Requisition, and Consumption.
  2. Barcode-Based Identification
    • GRN data fetched from SAP at the time of material receipt.
    • Individual and grouped barcode labels generated and applied to materials.
  3. Mobile-Based Quality Control (QC)
    • Android HHT devices used to scan and record material status during QC checks.
    • Only approved (OK) materials transferred to the store.
  4. Put-Away and Location Linking
    • Store users scanned both the material and location barcodes to establish digital linkages.
    • Improved bin-level accuracy and retrieval speed.
  5. Automated Pick List from SAP Requisition
    • Material requisitions pulled automatically from SAP and converted into pick lists in the DDAPL app.
    • Pickers received dynamic suggestions based on FIFO logic.
  6. Consumption Posting
    • On successful picking and issuance, material consumption data posted back to SAP, closing the loop.
  • Eliminated manual errors in material receiving, identification, and storage.
  • Increased traceability from GRN to consumption with SAP-linked updates at every stage.
  • Reduced put-away and pick time by guiding users to exact storage bins using barcode scans.
  • Enabled paperless operations and a secure audit trail of all inventory transactions.
  • Seamless SAP handshake with real-time data accuracy for production planning and inventory control

Additional Benefits and Future Enhancements

  • Multi-Location Deployment: System can be scaled to other plant stores and warehouses under a single cloud umbrella.
  • Offline Mode Capability: Enable offline transaction handling with sync-on-connect to ensure continuity in low network zones.
  • Inventory Heatmaps: Visualize movement and congestion within stores to optimize bin layout.
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