Logistics supply chain visibility solutions
Our client is a leading perishable goods manufacturer, producing over 500,000 loaves of high quality bread in various sizes and brands. From the gluten free premium brand to the all wheat and multi grain variety, the stuffed bread and parbaked frozen for microwave cooking.
With over 50 delivery trucks, the bread factory works 27 x 7 basis, supplying their bread products to over 500 outlets across the country using a hub and spoke warehouse model. The temperature and humidity controlled storage units are strategically located near the retail clusters near major cities and towns to ensure just in time delivery.
The operations control unit, located adjacent to the factory has a staff strength of 10 people to monitor routine works such as packing, shipment, delivery at warehouse, taking orders from retail outlets, keeping track of enroute theft, monitoring truck routes, fuel consumption, delivery schedules, proof of delivery, invoicing, credit control, internal audits and customer feedback.
The client has installed traditional GPS tracking solutions to track the movement of all 50 trucks for operations to ascertain the pickup and delivery schedules.
The client had problems in getting real time information on product theft, wrong shipments, improper unloading, environment control at warehouses and retail counters. The premium brand of their products were in great demand and the retailers had long term business dealings with the client. However there were frequent disputes regarding short / wrong shipment which lead to additional paper work.
Our Internet Of Things solution comprised of deployment of long range, reusable IOT tags on the trays that held 20 loaves of bread each. The IOT sensors ensured complete track and trace of the bread racks from factory production, dispatch section to loading in truck, movement to nearest warehouse, arrival logging, dispatch to the retail centre and the arrival date and time at the respective centres.
The information from all these locations were accumulated on a cloud platform and shared with the existing supply chain logistics ERP suite through our restful Application Programming Interface.
Benefits of sensor integrated logistics visibility solutions
- Reduction in theft of products en route
- Instant Proof of Delivery from Retail counters
- Improved truck availability information
- Higher utilisation of dispatch yard
- Better stacking and temperature control in the warehouse
- Improved efficiency in dispatch, loading and delivery
- High satisfaction among the retail stores
- Proper scheduling and time management for trucks
- Integrated with existing GPS and ERP software
The overall cost of the solution was well within budget – which included the pricing for the wireless tracking tags, the access points, integration with existing GPS system and the cloud enabled information system that provided the alerts and push messages to operations control, warehouse in charge, truck driver and the owner of the retail shop.
In the second phase of the logistics visibility project, the client budgeted for monitoring solutions within each retail outlet to closely understand the temperature humidity conditions inside the storage unit to ensure the assured shelf life for the bread. Various equipment such as power generators, blowers, dryers, choppers and other equipment are going to be armed with IOT sensors for improved asset efficiency.