End-to-End Material Traceability & Dispatch Automation
100% real-time barcode validation ensured zero counterfeit bulbs passed through production.
25,000+ bulbs/day scanned automatically with minimal human intervention.
Instant rejection via PLC for incorrect or duplicate barcodes, improving traceability and efficiency.
The Challenge
The Solution
The Results
The customer required an integrated solution to track material movement from label printing to truck loading and dispatch, while generating transaction reports for complete operational visibility and traceability.
The key objectives were to establish unique identification for every product, reduce manual effort in warehouse operations, improve transaction accuracy, and enable reliable tracking of material movement across the warehouse and dispatch process.
The solution was designed around a centralized web application, barcode-based data capture, an Industrial Mobile Terminal, and SAP integration to create a connected Track and Trace System.
The key challenges included:
- Requirement for unique product identification for tracking materials throughout the warehouse and dispatch process.
- Need to reduce manual effort during warehouse inward and outward operations.
- Requirement to improve transaction accuracy and reduce manual data-entry errors.
- Need for reliable tracking of material movement from label printing through warehouse storage to truck loading and dispatch.
- Requirement for SAP-based validation of material and dispatch transactions.
- Need for centralized transaction reporting and historical traceability.
- Requirement to reduce manual intervention by connecting label generation, warehouse scanning, SAP validation and transaction reporting.
The solution consisted of three key components:
1. Web Application
- Label Printing
- Master Data Management
- Transaction Reports
- Material and transaction monitoring
The web application provides centralized control over master data, label generation, and transaction reporting.
The centralized application also supports the functionality required for WMS software, enabling connected warehouse transaction management.
2. Industrial Mobile Terminal
The warehouse operations were digitized using an Industrial Mobile Terminal equipped for barcode-based data capture.
- Warehouse Inward
- Warehouse Outward / Dispatch
- Barcode scanning
- Material identification
- Digital transaction recording
The mobile workflow reduces manual data entry and supports faster material movement tracking.
The barcode-based workflow also functions as warehouse inventory tracking software, providing digital visibility of material movement across warehouse operations.
3. SAP Integration
The solution integrates with SAP to retrieve material and dispatch-related information and validate transactions against relevant SAP documents.
Together, these components form a software-driven Track and Trace Software solution that connects material identification, warehouse transactions, dispatch and reporting.
Implementation
1. Label Printing – Web Application
The user selects the Material Code, enters the Batch Number and Quantity, and generates product labels using the available master data.
The generated labels provide a unique identification mechanism for tracking materials through subsequent warehouse operations.
Depending on the deployment requirements, the label-printing workflow can work with compatible Desktop Barcode Printers or Thermal Transfer Desktop Printers for barcode label generation.
2. Warehouse Inward – Industrial Mobile Terminal
The warehouse operator scans the material barcode using the Industrial Mobile Terminal to retrieve the complete material details associated with the pallet.
The operator then selects the relevant Storage Location and saves the inward transaction digitally.
Barcode-based data capture eliminates repetitive manual entry and improves the accuracy of warehouse transaction records.
3. Warehouse Outward / Dispatch – Industrial Mobile Terminal
The operator selects the relevant SAP Document Number and scans the materials planned for dispatch using the mobile barcode scanning device.
The system validates the scanned material against the dispatch information. After successful validation, the outward transaction is completed and the material movement is recorded digitally.
This creates a connected process from warehouse outward to truck loading and dispatch, providing improved visibility into material movement.
4. Masters & Reports – Web Application
The web application provides centralized access to master data and transaction reports, enabling users to monitor material movement and retrieve historical transaction information.
The reporting layer supports traceability across the complete process and provides a digital record of warehouse and dispatch transactions.
The implementation of the integrated material traceability and dispatch automation solution delivered the following outcomes:
Unique Product Identification
Every product is assigned a unique identifier, enabling easier identification and tracking throughout the warehouse and dispatch process.
Reduced Inward & Dispatch Time
Barcode scanning through an Industrial Mobile Terminal eliminates repetitive manual data entry and helps speed up warehouse transactions.
Accurate Material Traceability
The system provides end-to-end visibility of material movement from:
Label Printing → Warehouse Inward → Storage → Warehouse Outward → Truck Loading / Dispatch
This establishes a practical Track and Trace System for material movement.
Improved Data Accuracy
Barcode-based data capture and SAP integration reduce manual errors and improve the accuracy of material and dispatch transactions.
Centralized Reporting
The web application provides centralized transaction reports for monitoring, analysis and historical traceability.
Reduced Manual Intervention
The software-driven workflow connects label generation, warehouse scanning, SAP validation and transaction reporting, reducing dependency on manual data recording.
The integrated approach also provides a foundation for Warehouse Management Software India requirements where connected warehouse processes and digital material tracking are required.
Additional Benefits and Future Enhancements
Future Scope
The solution can be extended to additional manufacturing plants, particularly plants where smaller products are manufactured.
The proposed next phase will introduce further automation through:
- QR Code Generation with Online Printing
- Vision-Based Product Scanning
- Automated Product Identification
- Automated Tracking & Traceability
These enhancements can further minimize manual intervention and support a scalable Manufacturing Automation Software environment for product identification and traceability across multiple plants.
The future roadmap also creates opportunities to incorporate Industry 4.0 Software capabilities, including connected data capture, automated identification and real-time process visibility.
The solution can also be extended as part of broader Warehouse Automation Solutions for connected warehouse and dispatch operations.
End-to-End Process
WEB APPLICATION
Label Printing
INDUSTRIAL MOBILE TERMINAL
Warehouse Inward
STORAGE
Material Storage
INDUSTRIAL MOBILE TERMINAL
Warehouse Outward
TRUCK LOADING / DISPATCH
WEB APPLICATION
Reports & Traceability
Key
Outcomes
- Unique Identification
- Faster Operations
- Accurate Traceability
- Centralized Reporting
- SAP Integration
Technology & Solution Highlights
- Track and Trace Software
- Track and Trace System
- Industrial Automation Software
- Manufacturing Automation Software
- Industrial Mobile Terminal
- Mobile Barcode Scanner Device
- 2D Barcode Scanner
- Desktop Barcode Printer
- Thermal Transfer Desktop Printer
- SAP Integration
- Barcode-Based Material Tracking
- Automated Product Identification
