100% mold traceability from receipt to return enabled via RFID + QR integration.
Zero manual errors in picking and issuance with guided RFID scans and digital pick lists.
Automated lifecycle alerts improved mold utilization and reduced downtime risk.
The Challenge
The Solution
The Results
- Difficulty in tracking mold movement across warehouse and production units.
- Delays and mismatches in mold issuance and receipt cycles.
- Lack of real-time visibility into mold servicing, reconditioning, and scrapping processes.
- Inability to automate mold lifecycle alerts such as mold returns and shot count limits.
DDAPL provided a fully integrated RFID + Barcode-enabled Mold Tracking System, combining smart traceability software, QR-encoded RFID tags, and Android-based scanning devices. Key solution components included:
- RFID Tags with QR Codes attached at the time of mold receipt.
- Android scanning devices supporting both RFID and barcode scans.
- DDAPL Traceability App synced with the customer’s ERP for seamless data integration.
Solution Highlights
- Mold Receiving & Tagging
- Molds are received against Purchase Orders and tagged with unique RFID+QR code identifiers.
- Tags are physically affixed to each mold to enable end-to-end tracking.
- Warehouse Mapping
- Warehouse user scans the mold barcode and location code to digitally link each mold to its physical storage location.
- Production Planning & Mold Picking
- ERP-generated production orders are auto-fetched into DDAPL.
- Mold pick lists are generated and assigned to warehouse pickers.
- Pickers receive guided instructions through the mobile app to locate and scan the correct molds using RFID-enabled devices.
- Production Issuance & Monitoring
- Molds are marked as issued to production upon scan.
- ERP sync provides daily production counts, enabling real-time monitoring.
- Post-production, the app auto-alerts for mold return if delays are detected.
- Servicing, Dispatch & Receipt
- Returnable delivery challans (RDCs) for mold servicing are imported from ERP.
- The app generates pick lists for servicing and verifies dispatch/loading via RFID scans.
- Upon mold return, RFID-based receipt confirms the transaction and updates the system.
- Auto Alerts & Mold Lifecycle Control
- Automated reminders are triggered if molds are not returned in expected timelines.
- Shot counts for molds are tracked; once limits are reached, scrapping reports are generated.
- For reconditioned molds, warehouse users can scan to reset shot limits as required.
- 100% Traceability across mold movement lifecycle—from supplier receipt to production and return.
- Reduced manual effort and errors through digital pick lists and guided mold identification.
- Real-time inventory status, mold location, and production mapping enabled agile planning.
- Automated reminders & lifecycle reports enhanced mold utilization, compliance, and asset life extension.
Other Exciting Projects
We have Worked On!
Additional Benefits and Future Enhancements
- Mold Performance Metrics: Generate efficiency scores and lifecycle analysis for each mold based on production data.
- Mobile Notifications: Real-time alerts for pending returns, high shot counts, or servicing overdue sent to user devices.
- Integration with Vendor Portals: Direct visibility into vendor delivery timelines and servicing turnaround.
