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Overcoming inaccurate inventory counts
Inaccurate inventory counts lead to discrepancies and require manual cycle counting to correct within the manufacturing industry. The root cause is typically a reliance on legacy paper processes and disconnected tracking systems. These manual workflows inevitably introduce human error, forcing workers to spend valuable time physically searching for misplaced assets and verifying stock levels rather than focusing on core production tasks.
The negative consequences of this challenge are severe. Without accurate visibility, manufacturing operations face unexpected stockouts that cause massive operational bottlenecks. The persistent need for tedious manual counts creates huge inefficiencies and high costs, ultimately leading to delayed order fulfilments, wasted labour hours, lost revenue, and significant customer dissatisfaction across the facility.
The streamlined inventory counting solution
Implementing the TC5 Series, RFD40, and Tablets provides a cohesive workflow to address severe tracking discrepancies. This specific hardware configuration directly targets manual errors by replacing them with reliable automated data capture, delivering improved inventory accuracy and reduced stockouts. This combination modernises manufacturing operations.
Potential benefits
By shifting from tedious manual counts to rapid cycle tracking, organisations gain a new level of control. These optimised workflows translate complex challenges into tangible operational advantages and reliable inventory metrics.
Improved inventory accuracy
transitioning to rapid and accurate RFID cycle counting
Reduced stockouts
providing organisations a new level of control over inventory
More efficient use of warehouse space
making inventory availability a competitive advantage
How the solution works
Capture real time data
Equipping workers with the TC5 Series fundamentally changes the tracking process. As users move through the facility, this mobile computer acts as a powerful handheld device to scan items instantly. It is highly effective at capturing data accurately, making it the ideal choice for eliminating tedious manual counts and establishing a solid foundation for continuous inventory management.
Enhance capture capabilities with advanced sled attachments
To further extend these capabilities, workers attach the RFD40 to their mobile computers. This addition allows the system to accurately read multiple tags simultaneously and identify any discrepancies from greater distances. By significantly expanding the read area, this attachment proves exceptionally capable of updating inventory counts in real-time across dynamic manufacturing environments.
Direct workflows and reviewing discrepancy alerts
Once the data is captured, workers use ET401 tablet to visualise the updated inventory records and manage complex tasks. The system uses these rugged screens to direct them to specific locations for counting based on immediate needs or flagged errors. By providing a clear and accessible interface, this device keeps operations perfectly aligned and highly productive.
Seamlessly adapt from warehouse floor to forklift
The ET60 easily transitions from a portable, handheld tablet on the warehouse floor to a vehicle-mounted terminal on a forklift, allowing managers to reallocate resources on the fly. This makes it a powerful tool to streamline cycle counting, enabling faster, more frequent, and highly accurate inventory tracking. It securely locks into a rugged vehicle dock built to withstand heavy vibrations, constant pounding, and shocks from driving over ramps and bumps in demanding plant or warehouse environments. The touchscreen is also specifically tuned for gloved fingers. And when paired with the rugged vehicle keyboard, operators can perform high-speed, tactile data entry.
Maximising value through inventory control
Investing in advanced counting capabilities delivers measurable financial benefits by minimising production downtime and optimising warehouse space. Organisations achieve a significant competitive advantage through reliable stock availability and highly efficient resource utilisation.
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.
