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Factory Reduces Order-Fulfillment Time by 20 Percent
Leal, which produces and markets personal protective equipment, has adopted an RFID solution from PC Sistemas, along with Totvs' enterprise resource planning system.
"This functionality ensures that our customers and their employees are protected from accidents, reducing the risk of non-compliance in work-safety audits," explains Jacques Levy, Fair Trade's managing partner. With the RFID system, he says, companies that buy from Leal will be advised when inspection and expiry deadlines are near.
The implementation was conducted in three phases. During the first phase, auditing, investment was made in stock control, focusing on the inventory of a specific line of insulated gloves and blankets. Fifteen thousand items were tagged with RFID tags supplied by Valid and CCRR, after which information was checked to determine whether there were any undue variations.
During the second stage, improvements were made to the process of buying fabric rolls. RFID tags identify each roll, which measures 170 meters in length, and indicate how many meters have already been used in production, as well as how many remain. For the third phase, the raw material enters the warehouse already identified via RFID, and orders are fulfilled using the same technology.
"During testing, we identify opportunities to optimize our processes," Siqueira says. "Due to the way the pieces are stored, especially in the case of clothing, there can be divergence. That's why we decided to redesign our storage, to improve the operation's productivity."
The deployment has resulted in additional developments, and the company's next steps will be to tailor and perfect the internal labels for each type of product, and to standardize the use of RFID in accordance with GS1's Electronic Product Code (EPC) standard.
"Totvs works to be not only a technology supplier, but a partner in the development of the customer business," says Gustavo Bastos, Totvs' supply chain VP. "The project developed at Leal showed that the choice of a tool, such as RFID, can bring improvements in the processes of a company, giving space to grow and gain more competitiveness."
"Deploying RFID was a positive experience," Siqueira reports. "In fact, there were all sorts of experience, because the RFID system is made up of hardware, software and labels, which have at least three different suppliers. So when there is a problem, it is difficult to coordinate a resolution with the three suppliers at the same time. The challenge is to read RFID pallets with total reliability. We still have problems reading pallets in the portals. "
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