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ABOUT THE CLIENT
Press Glass is one of the largest manufacturers of glass for the construction industry in Europe, operating in a global model with plants in many countries. The company executes orders for large distribution networks and the industrial sector. Due to the intense flow of goods and the complex circulation of semi-finished products, the efficiency of warehouse logistics has a direct and critical impact on the productivity of its entire production.
About the project
Press Glass approached us with the need to streamline warehouse processes, which were burdened by manual record-keeping and a lack of coherent work synchronization between departments
this resulted in low efficiency of loading and unloading operations and an increased risk of operational errors. The key challenge was to implement a solution that would organize the data flow and automate key warehouse operations.
As part of the project, we created the Android Scanner App, utilizing Zebra terminals and RFID and QR technologies. Integration with the ERP system, automatic error verification, and full traceability of user work allowed us to achieve high process predictability and significantly increase operational efficiency.
INITIAL REQUIREMENTS / CONSULTING
The need for process standardization
The client noticed that the existing, manual-heavy methods were failing to keep up with the growing scale of operations. The organization needed a reliable tool integrating live data with the ERP and operating stably in a multi-location and intensive-use environment.
Mapping the work environment
We started with a rigorous mapping of the processes in the “as is” state, identifying the actual sequences of actions, exceptions, and informal practices of operators. Only this expert analysis allowed for the design of a feasible and fully intuitive target “to be” model.
CHALLENGE / ANALYSIS
Discrepancy of processes between plants
Warehouse record-keeping had developed over the years in various variants depending on the individual plants. A major challenge was to standardize all these operations to eliminate inefficiencies while maintaining the agility and acceptance of the teams.
Extreme ergonomic requirements
The new application’s interface had to meet the harsh conditions of the warehouse environment. Operators work in constant motion, often on forklifts and wearing work gloves, so the software had to be quick to use (even with one hand) and completely error-proof.
Live synchronization with ERP and automation
The system could not operate in a vacuum. An absolute requirement was to create mechanisms that would exchange live data with the client’s existing ERP system without any delays, building a consistent, central “single source of truth” for the entire production.
PROJECT GOALS
The project aimed primarily to increase the efficiency of intra-warehouse logistics and completely eliminate critical errors resulting from manual record-keeping. We focused on standardizing operational standards across the global organization while maintaining the highest ergonomics and intuitive equipment use.
Increasing operational predictability
Building a cohesive record-keeping system across all of the company’s global locations, guaranteeing full compliance of registered traffic with production schedules and the central ERP system.
Shortening the time of logistics processes
Drastically speeding up loading and unloading by completely eliminating manual, paper-based bureaucracy and implementing instant validation of emerging system errors.
Maximizing operator ergonomics
Creating a software environment tailored to demanding physical work, taking into account the use of mobile devices in conditions of constant movement, rotation, and time pressure.
Standardization of decision-making processes (Rules Engine)
Implementing mechanisms for precise tracking of every performed action, providing management with hard data to analyze quality, efficiency, and resource load over time.
Global unification of standards
Translating local, developed work methods into a single standardized scheme for the entire organization, improving communication and significantly shortening the reaction time to any random events in the warehouse.
Solution description
The designed Android Scanner App constitutes the target and ergonomic environment for operators. It operates reliably on robust Zebra TC8000 industrial terminals (RFID and QR readers). Its full, instant integration with the central ERP system ensures that every action performed in the warehouse supports and verifies the production planning processes of the entire company in real-time.
PROJECT DETAILS / IMPLEMENTATION
The core of the solution is a highly ergonomic application running on durable Zebra TC8000 terminals, which communicates in real-time with the central Press Glass ERP architecture.
Data collected from RFID and QR scanners is subject to instant, fraction-of-a-second system validation at the device level, effectively rejecting mistakes even before packages are approved.
The software was designed specifically with the efficient functioning of the operator in extreme warehouse conditions in mind, reducing the need to use both hands.
The result is a paperless, controlled work environment recording full audit activity and capable of handling any modifications in the further digitalization of the logistics chain.
Android Scanner App
Creation of dedicated operational software that works reliably on rugged, industrial Zebra TC8000 mobile terminals.
Support for RFID and QR code technologies
Implementation of the ability to instantly scan pallets, individual packages, and specific warehouse locations using built-in readers.
Ergonomic operational interface
Designing a UX that allows warehouse workers to handle key operations with just one hand and while wearing work gloves, which is critical when driving forklifts.
Instant ERP integration
Creating a seamless connection ensuring that every operation is reflected in real-time within the company’s central production planning and logistics processes.
Automatic data validators
Building intelligent real-time verification mechanisms that successfully eliminate incorrect scans, wrong locations, and mistakes in load assembly.
Audit trail recording
The software collects the exact activity of every single user, providing precise data for controlling process safety and quality.
Results and business
impact
The implementation of the Android Scanner App brought Press Glass clearly measurable results and completely rebuilt the way warehouses work. The tool integrated previously dispersed operational environments into a single coherent record-keeping system, constituting a stable foundation for further digitalization of the enterprise.
27% increase in operational efficiency: Significant and measurable improvement in the overall efficiency of intra-warehouse processes after complete verification of the implemented software.
Complete elimination of paper orders: Transition to tasks planned and verified entirely electronically, which permanently eliminated errors resulting from illegible documents and unnecessary downtime.
Access to controlling data (ERP): Company authorities and managers gained access to logistical analyses with calculations of individual cycle times, real loads, and the number of errors of individual shifts.
Significantly faster flow of information: Instant and automated communication between the warehouse and production drastically reduced the reaction time to errors, slowdowns, and crises.
Integrated reporting for the board: Thanks to the modular architecture of the Scanner App, Press Glass gained a tool ready for easy addition and scaling to new logistics areas in the near future.
Client testimonial
“Collaboration with the development team was very valuable to us, because from the beginning they were able to understand the specifics of our warehouses’ work and the real needs of the operators. The process of analyzing and mapping activities went smoothly, and the designers quickly translated our requirements into practical solutions that immediately improved the quality of work after implementation. The entire execution went transparently and professionally, and the final result definitely confirmed the competence and experience of the company we collaborated with.”
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