Hybrid RFID gate and forklift solution ensures zero errors in outgoing goods

The project

Avoid incorrect loading
Recognize and rectify errors immediately
Prevent damage running into millions

RFID Lösungen Digitalisierung Lager - RFID Konsortium

The solution

Spare parts deliveries for the sea route are loaded completely, correctly and for the right destination
100% Track & Trace sea freight
Ergonomic forklift solution combined with RFID gates at loading gates

Key Facts – The Goals Achieved

No loading errors, no complaints

100 % match of the physical and digital output

Efficient outgoing goods process

Real-time transparency of all shipments

Recognize and correct errors immediately and not only after 6 weeks

Quality assurance

Project Requirements

Containers are shipped to different countries and must be loaded correctly
Loading errors lead to consequential process errors, such as incorrect customs declarations at the destination and customer complaints
Each handling unit must be brought to the correct loading line
“On-the-fly” corrections must be possible

Special features:

There were three special features in this project:

The special communication between the forklift and RFID gate was a challenge.
An outdated Android 6.1.
operating system of the forklift truck had to work together with the modern software and the RFID readers.
It should also be possible to spontaneously relabel cartons or handling units (HU) that were missing the RFID transponder.
The articles should be mapped into the ERP system with a short delay.
When loading the containers, the goods could not be inadvertently booked out again during maneuvering.
Special gate filters ensured that all items were only recorded and booked once.

Implementation of key objectives:

All spare parts are recorded and tracked down to the smallest level
Every consignment goes into the correct container
Avoid operational costs due to incorrect loads

"The RFID reader is attached directly in front of the fork on the forklift truck. It automatically records what we pick up. In the past, we always had to get down and scan by hand. Now we stay seated, pick up the pallet, drive it through the gate and place it in the container. It's much quicker. So many mistakes used to happen. Today, we know that we are bringing the right spare parts to where they are needed."

Forklift driver about the project

Loading sea freight containers without errors

The automotive spare parts business is very important for the after-sales market. After all, it is about customer loyalty. Speed and availability of parts for planned repairs are critical factors here. If the end customer has a positive experience with the service, they will remain loyal to the car brand. Especially in the premium segment. In this project for a German car manufacturer that ships its spare parts from a central distribution center all over the world, the focus was specifically on the outgoing goods process. This is so sensitive because incorrectly loaded goods only become a problem at the port of destination after six weeks at sea. With a combined forklift-gate solution, we have implemented error-free, reliable loading in this project. The forklift drivers register at the respective gate. They are then also able to control the gate: Start the loading, drive through and also close the loading again. In addition, all forklift drivers now know which zone they have to transport and park their consignment in. However, if a pallet is accidentally placed incorrectly, the error is audibly and visually visible via the forklift terminal and instructs the forklift driver to correct it immediately. When the forklift truck passes through the gate with the goods, the system checks that the correct goods have actually been loaded on the correct line. It is booked correctly directly in the ERP.