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Inventory Count System with Order Picker Receives Auto-ID System Award of Excellence
Significantly Improves Inventory Operation using RFID

September 24, 2013

Information management solution provider Toppan Forms Co., Ltd. (Toppan Forms hereunder) co-developed a patent pending "High Speed Inventory System with Order Picker Capability" with Yasuda Warehouse Co., Ltd. (Yasuda Warehouse hereunder) which was awarded the 15th Auto-ID System Grand Prize sponsored by Japan Automatic Identification Systems Association. The inventory system is actually being operated at Yasuda Warehouse and the award was given for its achievement in significant effectiveness. Details on this system will be displayed at 15th Auto-ID Expo to be held in Koto-ku, Tokyo on September 25 - 27 which is sponsored by Japan Automatic Identification Systems Association.

Background

Previously, when conducting inventory count operations for document cartons, operators had to get on the order picker which was inefficient and dangerous due to work in high places. The system attaches RFID labels on document cartons allowing them to be individually identified using radio frequency. This enables high speed operation, lighter workload for the operators, and prevention of quality and labor accidents that lead to the customer and employee satisfaction.

How the System Works

In this system, four units of RFID Antennas are installed on both sides of the order picker totaling eight. Since the readers read both side of the aisle at once, warehouse inventory is completed in just a single round.

How Inoventory Count System with Order Picker Works

Features

  • 1. Significantly shortened time for inventory counting resulting in reduction of labour cost of the operators. The read speed in one hour is maximum 14,400 cartons which is 24 times faster than the conventional method shortening inventory count of 300 thousand cartons from 500 hours to 21 hours.
  • 2. Near 100% Readability Rate
    Installing eight antennas on both left and right sides allow both sides of the aisle to be read simultaneously with near 100% readability rate.
  • 3. Based on document carton storage rack record, readability strengths of radio frequency from both registered storage rack and non-registered location are recorded and compared. The rack with stronger readability over-writes the record as the most recently updated storage rack location.

Future Roadmap

Toppan Forms will market the system to companies that conduct inventory count in the warehouse and logistic center by customizing it to optimal forms.

Public Relations Department
General Affairs Division
TOPPAN FORMS CO., LTD.
1-7-3 Higashi Shimbashi, Minato-ku, Tokyo 105-8311, JAPAN
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