Fabchair - E-Dispatch using QR code (Automation in Dispatch of Finished products with Zero tolerance)

After replacing SAP B1 at Fabchair, we focused to implement Automation projects at Manufacturing area taking advantage of unlimited users license in ERPNext so that we can involve each employee in Production Planning, manufacturing & Despatch process.

Volume of dispatch is from 1000 Boxes to 1200 Boxes / Day.

Objective:

We worked on the vision that there should not be “Manual Data Entry” in ERP throughout the dispatch process to achieve,

-Accuracy in Dispatch

-Automating Invoice generation after material loaded in Truck

-Avoid wrong item, Quantity, incorrect Batch

-Avoid customer returns

ERP Process:

As a daily production plan, create a work order for the finished goods and take the print of QR code stickers. These stickers will be issued to Production department to paste on each box. Once the production is completed, boxes are stored at Finished Goods store.

For the dispatch plan, we have used “Pick List” for each customer. On the pick list, we have provided QR code scanner which will be used for scan the Box and pick the item quantity.

Once “Pick List” is completed, operator can submit the pick List. We have automated the process to create Sales Invoice, IRN generation and E-way Bill creation through system based on the Pick List quantity.

Challenges :

After completion of development, we started implementation of QR codes scanning on the shop floor. We observed that Scanning QR codes taking long time. existing QR code library was not auto focusing on QR code. So we tried with Bluetooth QR code handheld devices but no success. We tried with web based QR code scanning library of "Dynamsoft" which worked and speed with Beep sound ensured that QR code is scanned.

Benefits:

1. No hardware investment required since application is web based and works on any mobile devices.
2. Accurate despatch of Item and Quantity achieved.
3. Any person can just scan the Box using mobile phone - No person dependency
4. Mismatch of dispatched Quantity and Invoice quantity matched.
5. Time saved in Invoice creation process - Invoice created after Picklist submission.

Deployment :

This tool is deployed on ERPNext and also it can be deployed with existing ERP like SAP ECC, S4HANA, Oracle or any other current ERP.

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About Author:

Satish Aralkar is SAP consultant having 15 years of SAP implementation and 12 years of Domain experience in manufacturing. Currently working on ERPNext implementations, Automation and Digital Transformation.