RFID live inventory
tracking system.
**Client:** Precision Components India **Objective:** Replace slow barcode scans and manual ledger entries with a real-time tracking WMS using high-performance Zebra edge devices and industrial print printers.
1. Project Context & Industry Background
Industrial manufacturing facilities handling high-volume precision auto parts operate under tight delivery constraints. Components move rapidly from fabrication lines to heat-treatment chambers, chemical washes, final assembly, and export packaging. In such fast-paced environments, tracking stock locations and quantities is vital to prevent raw material shortages and assembly downtime.
The client, Precision Components India, operates a major automotive parts factory with over 8,000 active SKUs. Their legacy tracking relied on manual barcode sweeps. Operators scanned visual labels pallet-by-pallet, which took hours, required direct line-of-sight alignments, and resulted in double-scans and ledger lag. A hands-free, high-speed tracking system was required to inventory entire aisles instantly.
2. Operational Challenges
Deploying a live tracking WMS on a dynamic factory floor introduced several engineering challenges:
- Barcode Scanning Latency: Manual barcode scanning was slow and introduced bottlenecks at packing checkpoints, delaying outbound dispatches.
- Zebra Sled e-connector Integration: Handheld computers had to connect securely to RFID sleds, streaming tag data without dropping frames or losing battery power under continuous sweeps.
- Dynamic Label Encoding: Pallet labels had to contain both human-readable text and encoded RFID inlay chips, containing SKU, batch ID, and packaging date metrics.
- Wi-Fi dead zones: Metal rack shelving created wireless signal interference, requiring local offline caching to prevent data loss.
3. Technical Solution & Hardware Integration
We built a mobile-to-cloud WMS tracking engine integrated with high-performance Zebra hardware:
// Zebra TC27 & RFD4031 Sled Integration
We engineered a custom Android WMS application written in Kotlin, running on Zebra TC27 touch computers. The TC27 is mounted on a Zebra RFD4031 RFID sled via an integrated e-connector. This configuration provides read speeds of up to 1,300 tags per second. Operators sweep the scanner across multi-tier storage racks, capturing hundreds of pallets instantly.
// Zebra ZT411 Industrial Printer Configuration
At packaging stations, we installed Zebra ZT411 industrial printers equipped with RFID encoders. The central Odoo ERP dispatches ZPL commands containing print layouts and RFID data block codes. The printer writes the product SKU, batch number, and timestamp to the inlay microchip before printing the barcode labels.
// Asynchronous API Gateway & Deduplication
The mobile app caches scans locally in a Room database before batch uploading them to our FastAPI gateway via REST connections. The gateway filters duplicates, matches tag EPCs against shipping manifests, and updates stock balances in the PostgreSQL database in milliseconds.
4. Results & Impact
Inventory accuracy maintained across 8,000+ active parts.
Audit cycles reduced from 16 hours to less than 3 hours.
Dynamic RFID print queues automatically managed on packing lines.
Frequently Asked Questions
// DEPLOYMENT SUMMARY
Optimize your warehouse logistics.
We configure Zebra hardware and deploy RFID-enabled inventory database systems.