01
Client Profile & Background
A leading consumer goods manufacturer in Cikarang, Indonesia, operates a 50,000 sqm warehouse handling 10,000 SKUs with daily throughput of 15,000 pallets. The facility runs 24/7 with 200+ warehouse staff using manual paper-based processes. Inventory accuracy is critical to avoid stockouts during peak seasons.
The company’s existing ERP system (SAP ECC 6.0) is used for financials and procurement, but warehouse operations rely on disconnected spreadsheets and manual data entry. This leads to delays in inventory updates and frequent discrepancies between physical stock and system records.
02
Technical Challenge
The primary challenge was a 23% inventory inaccuracy rate, causing annual losses of over IDR 5 billion due to overstocking and stockouts. Manual data entry resulted in average 2-hour delays in updating SAP after goods receipt. During peak season, order fulfillment errors spiked to 8%, leading to customer penalties.
Additionally, the existing wireless network (legacy 802.11g) could not support real-time barcode scanning across the warehouse. Battery life of handheld scanners was insufficient for 12-hour shifts, requiring mid-shift replacements and downtime. The lack of integration between scanning devices and SAP meant that data had to be batch-uploaded, causing further delays.
03
Implemented Solution
Intilogy deployed a comprehensive barcode WMS integration using Microsoft SQL Server as the database backend, with Synology NAS for local storage and backup. The WMS platform chosen was VMware-based virtualized servers running on Lenovo ThinkSystem SR650. Barcode scanners (Honeywell Xenon 1900) were integrated via middleware that mapped scan events to SAP IDocs in real time.
The wireless network was upgraded to Cisco Wi-Fi 6 access points, ensuring low latency and high density support. Label printers (Zebra ZT610) were deployed at each receiving and shipping dock. The solution also included a custom mobile app for Android devices that provided offline scanning capabilities, syncing automatically when connectivity was restored.
04
Results & ROI
Post-implementation, inventory accuracy improved from 77% to 99.5%. Order fulfillment errors dropped to under 1%, and the 2-hour data entry delay was eliminated, achieving real-time SAP updates. The RPO (Recovery Point Objective) for inventory data was reduced from 24 hours to 1 hour thanks to Veeam backup integration.
The company reported a 30% increase in warehouse productivity, with labor costs reduced by IDR 1.2 billion annually. The ROI was realized within 8 months. Additionally, the solution enabled traceability for regulatory compliance and provided analytics for demand forecasting. The upgraded networking infrastructure also supported future IoT initiatives.
