01
Client Profile & Background
A large-scale manufacturing company in Bekasi operates a 50,000 sqm warehouse that manages over 200,000 SKUs of automotive spare parts. The facility processes 5,000 inbound and outbound transactions daily, relying on manual barcode scanning for inventory tracking. The company has been in operation for 15 years and serves major automotive brands across Indonesia. Their existing server and storage infrastructure includes Dell PowerEdge servers and a QNAP NAS for backup, but the warehouse operations are heavily dependent on paper-based processes and manual data entry.
02
Technical Challenge
The manual barcode scanning process caused a 12% error rate in inventory counts, leading to stock discrepancies worth over $500,000 annually. Cycle counting required 20 staff working 8-hour shifts, yet accuracy remained below 85%. The warehouse experienced 4-hour delays in locating specific pallets during peak production, causing assembly line stoppages. Additionally, the existing networking infrastructure, based on old Wi-Fi 4 access points, could not support the high-density data transmission from multiple handheld scanners simultaneously. The company needed to reduce inventory errors to below 0.5% and improve real-time visibility across the supply chain.
03
Implemented Solution
Intilogy deployed a comprehensive RFID solution using Impinj R700 readers and Monza R6 tags for pallet-level tracking. Fixed RFID portals were installed at all 12 dock doors, and 50 handheld readers (Zebra MC3390) were provided for staff. The middleware, hosted on HP ProLiant servers, integrated with the existing SAP ECC via Microsoft BizTalk. Edge computing nodes using Lenovo ThinkEdge SE450 filtered and processed tag reads locally to reduce latency. The network was upgraded to Cisco Catalyst 9300 switches and Wi-Fi 6 access points to handle the increased data traffic. For disaster recovery, Veeam backup software was configured to replicate RFID event logs to a Synology NAS at a secondary site.
04
Results & ROI
Post-implementation, inventory accuracy improved from 85% to 99.8%, reducing stock discrepancies by $450,000 annually. Cycle counting time dropped from 8 hours to 30 minutes per shift, freeing up 15 staff for other tasks. Pallet location time decreased from 4 hours to under 5 minutes, eliminating production line stoppages. The RPO for RFID data was reduced from 24 hours to 1 hour using Veeam continuous backup. The company achieved a full ROI within 8 months and plans to expand RFID to their other warehouses in Java and Sumatra.
