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Shortages of returnable containers halt production
When inventory falls below safety stock levels, a shortage of returnable containers and totes at a kitting station can immediately halt production. In fast-paced manufacturing environments, relying on manual searches and guesswork to locate these essential assets leads to critical assembly line delays. Supervisors lack the necessary visibility to quickly find available totes, disrupting workflows and preventing material handling teams from efficiently replenishing kitting stations on time.
The negative consequences of these operational bottlenecks extend beyond simple delays. Unnecessary production stoppages lead to lost revenue and decreased in overall facility productivity. Furthermore, inaccurate inventory tracking often forces manufacturers to incur high costs by purchasing excess replacement containers when existing assets are simply misplaced, creating a cycle of inefficiency and financial loss.
The returnable container tracking solution
Zebra addresses these critical delays by providing a cohesive set of technologies that replace guesswork with automated real-time visibility. By accurately monitoring assets, this approach directly delivers reduced production stoppages and optimised use of returnable assets. Supervisors can quickly pinpoint exactly what they need to keep kitting stations fully supplied.
Potential benefits
Moving away from manual searches unlocks tangible outcomes that strengthen the supply chain. These strategic improvements reduce unnecessary costs and significantly improve overall daily productivity.
Reduced production stoppages
with real-time data that prevents critical assembly line delays
Optimised use of returnable assets
from continuous tracking that maximises tote and rack utilisation
Lower container replacement costs
because accurate inventory reduces the need to purchase excess containers
How the solution works
Gain continuous visibility into asset locations
Attaching RFID Tags to essential totes and containers establishes the foundation for continuous tracking throughout the facility. These durable tags are designed to be accurately scanned as they move through different zones, turning physical assets into visible data points. This creates a reliable and constant stream of location information, making it the ideal product to establish accurate inventory and prevent assets from being lost on the plant floor.
Capture accurate data as assets move
Deploying an RFID Reader automatically captures data from tagged containers as they travel across the production floor. The reader processes the information from the tags to provide accurate inventory levels without requiring manual scanning by staff. This automation provides the necessary input for integrated systems, making it a highly effective product for updating asset locations as totes move toward or away from kitting stations.
Visualise operations with a real-time map
The location data is then integrated into Workstation Connect, which provides a real-time map of the plant floor directly to supervisors. This software component aggregates the information from the readers, allowing managers to easily locate available totes and dispatch a material handling team to replenish the kitting station. By centralising this visibility, it becomes the optimal product for coordinating rapid responses and preventing critical assembly line delays.
Drive financial and operational ROI
Investing in automated tracking translates directly into lower container replacement costs and fewer production stoppages. These strategic improvements optimise the use of existing returnable assets, delivering clear financial value, and sustained daily productivity across facilities.
Note:
Use case figures and savings estimates are illustrative only and may be derived from customer data, projections, or controlled testing. They do not represent guaranteed results, and actual outcomes will vary by application; customers should consult a Zebra sales representative to evaluate their specific environment.
