Material Flow 3.0 to Automate Lean Replenishment Methods

Zebra Technologies Unveils Material Flow 3.0 to Automate Lean Replenishment Methods
Introduction of Material Flow 3.0 and WhereCall V Address Customer Demand For Greater Replenishment Triggers, More Dynamic Reporting

Chicago, Ill., Mar. 21, 2011— Zebra Technologies Corporation (NASDAQ: ZBRA), a global leader in specialty printing and automatic identification solutions, today announces the release of Material Flow 3.0 at ProMat® 2011 (Booth #4561). A major upgrade to Zebra's Material Replenishment solution, Material Flow 3.0 is a web-based, comprehensive enterprise execution management solution that allows industrial manufacturers to optimise their entire replenisment process. Material Flow 3.0 ensures the correct parts are in the right place in a timely manner during the manufacturing process by automating lean replenishment methods and providing more replenishment trigger methods, improved reporting and new communication tools.

Responding to industry demand and Zebra customer input, Material Flow 3.0 includes several enhancements that provide greater flexibility over the previous iterations. Most notably, the solution now features broadcast triggers which allow customers to call parts automatically without human initiation. Replenishment calls are made based on usage derived from the inventory list and a part's position in the assembly line. Additionally, Material Flow 3.0 includes several enhancements that provide end users with greater reliability and increased efficiency, including:

  • Goods Return Process: Sends "Reverse" parts calls when parts need to be removed from the assembly line
  •  Button Changeover Process: AllowsWhereCall, a small wireless call button, to be quickly reassigned to alternate part routes adding flexibility to the line
  • Dual trigger electronic Kanban: Two-button trigger dually located on the consumption end and manufacturing end to communicate inventories simultaneously

"Customer feedback is paramount to our solution development and much of the new functionality of Material Flow Replenishment 3.0 comes from the input we receive from them," said Mike Mulligan, director, manufacturing solutions. "This input enables us to create innovative solutions for industrial manufacturers that address the business problems they face."

In an unpredictable economy, translating technology acquisitions into return on investment (ROI) is essential to investment decisions. By reducing labor costs by 15 to 20 percent, reducing excess inventory and increasing asset utilisation by five to 10 percent,Material Flow 3.0 delivers compelling returns.

Zebra Also Introduces WhereCall V
Also on display at ProMat will be the newest product in the WhereCall line. WhereCall V, based on the technology from WhereCall IV and the exterior of WhereCall III, is a wireless call button designed to make parts requests without requiring any hardwired connectivity. It provides operator feedback automatically on its LCD display. WhereCall V is available as an extension of Material Flow 3.0 or independently.

For additional information and product demos, visit Zebra at ProMat booth #4561 or online at

About Zebra Technologies
Zebra Technologies Corporation (NASDAQ: ZBRA) provides the broadest range of innovative technology solutions to identify, track, and manage the deployment of critical assets for improved business efficiency. Zebra's core technologies include reliable on-demand printer and state-of-the-art software and hardware solutions. By enabling improvements in sourcing, visibility, security and accuracy, Zebra helps its customers to put the right asset in the right place at the right time. Zebra serves more than 90 percent of Fortune 500 companies worldwide.

For more information about Zebra's solutions, visit

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