01
Client Profile & Background
A large manufacturing company in Bekasi operates a 50-hectare logistics yard handling over 200 trucks daily. The yard stores raw materials and finished goods, with heavy forklifts and cranes moving constantly. The company needed a wireless network to enable real-time inventory tracking and automate gate operations. Previously, they relied on manual processes with paper logs, causing delays and errors. The yard's outdoor environment, with metal containers and moving equipment, posed significant RF challenges. The company had an existing IT infrastructure but no wireless coverage outdoors. They required a solution that could integrate with their ERP system and support future IoT devices.
02
Technical Challenge
The primary challenge was providing reliable wireless coverage across 50 hectares with less than 1% packet loss. The yard had multiple obstructions like container stacks up to 12 meters high and moving metal objects causing signal reflections. Additionally, the network needed to support over 500 concurrent devices, including GPS trackers on forklifts, RFID readers at gates, and handheld scanners for workers. The existing server and storage infrastructure was located 300 meters away, requiring high-capacity backhaul. The client also required 99.9% uptime, as any downtime would halt yard operations, costing approximately $10,000 per hour. Environmental factors like heavy rain and extreme heat (up to 40°C) demanded ruggedized equipment. The previous attempt with consumer-grade APs resulted in 30% connection drops and 5-second latency, making real-time tracking impossible.
03
Implemented Solution
The implementation took 4 weeks, with minimal disruption to yard operations. We tested coverage using a drone with a spectrum analyzer to ensure signal strength above -70 dBm across 95% of the yard. The network supports up to 1,000 concurrent devices with latency under 10 ms. Redundant power over Ethernet (PoE) injectors with battery backup ensure uptime during power outages. The client also adopted Veeam backup for configuration files to enable quick recovery in case of AP failure.
04
Results & ROI
Post-implementation, the yard achieved 99.95% wireless uptime over 6 months. Truck turnaround time decreased by 35%, from 45 minutes to 29 minutes on average. Inventory accuracy improved to 99.5% from 92%, reducing stock discrepancies. The automated gate system using RFID reduced manual labor by 60%, saving $120,000 annually. The network also enabled real-time GPS tracking of forklifts, reducing idle time by 20%. The client reported a full ROI within 8 months. Additionally, the solution scaled easily to support 50 additional IoT sensors for environmental monitoring. The enterprise WiFi solution has become a benchmark for other facilities in the group.
