RFID-Driven Warehouse Efficiency for Leading Plastic Goods Manufacturer

Client Overview

Company: Leading Plastic Goods Manufacturer
Location: India
Industry: Manufacturing – Plastic Products (Chairs, Tables, Household Goods)
Solution Used: RFID Inventory Tracking, Fixed Reader Automation, Mobile Handheld Scanning
Use Case: Real-time tracking and management of finished goods across multiple warehouses

The Challenge

As one of India’s largest plastic goods manufacturers, the client operated several large warehouses storing thousands of finished products. While their raw material tracking was efficient, they struggled to manage finished goods post-production. Products were stacked in bulk, making it extremely difficult to:

• Identify where specific items were stored
• Track inventory movements between warehouse zones
• Perform accurate stock counts
• Prevent unauthorized goods from leaving the premises

This lack of visibility led to delayed dispatches, frequent misplacements, and inefficient use of warehouse space.

The DreamzCMMS Solution

DreamzCMMS deployed an Rfid-Based Warehouse Automation Solution that digitized and streamlined the client’s post-production inventory management.

Key solution elements included:

• RFID tagging of all finished goods to create a complete, digital inventory.
• Defined warehouse zones with fixed RFID readers to detect and update product movement automatically.
• Gate-in/gate-out automation using RFID readers to prevent unauthorized item exits and ensure accurate dispatch control.
• Handheld RFID scanners enabling quick and accurate stock-taking for any warehouse at any time.

With this integrated RFID solution, the client achieved complete visibility into their finished goods inventory across all warehouses, eliminating manual tracking challenges.

Implementation Timeline

• Week 1–2: Warehouse zoning and RFID reader installation
• Week 3: Tagging and system integration with DreamzCMMS platform
• Week 4: Staff training and system go-live
• Month 2 onward: Optimization and full automation rollout across all warehouses

Key Features Utilized

• RFID Tagging and Zone-based Tracking
• Fixed Readers for Real-Time Location Updates
• Handheld Scanners for Instant Stock Audits
• Gate-in/Gate-out Access Control
• Centralized Dashboard for Multi-Warehouse Monitoring

Key Results / Outcomes

• 90% faster stock-taking process using handheld RFID scanners
• 70% improvement in dispatch accuracy, minimizing mix-ups and delivery delays
• 100% visibility across all warehouse locations, ensuring real-time stock awareness
• 50% reduction in manual labor effort related to inventory tracking and verification
• Complete elimination of unauthorized product movement, with gate-level RFID alerts

Technology Stack

DreamzCMMS Cloud Platform, RFID Tagging & Fixed Reader Automation, Mobile Handheld Scanning Devices, Real-Time Dashboard & Alerts

Testimonial