Overview
This leading manufacturer in India, with typical Indian traditional manufacturing processes trusting workers, was interested in applying AI to improve their process due to increased labor shortage and rising costs of skilled labor.
When Vikbot visited their plant, we identified too many places to apply AI vision automation and selected some top high ROI projects. Dispatch was one of their leading inventory leakage points.
Challenge
The company faced significant challenges in their dispatch process:
- Customers were unhappy receiving wrong shipments
- Short shipments and excess shipments were common
- Trust issues with customers due to inconsistent deliveries
- Revenue loss from shipment errors and customer dissatisfaction
- Theft and malpractices through unwanted material movements
Solution
We suggested our AI Dispatch Tracker hardware which streamlined their dispatch process with the following capabilities:
1. Accurate Scanning
- Every single item scanned accurately
- No material can leave the warehouse without scanning
- Real-time verification against dispatch orders
- Automated error detection and alerts
2. Visual Fencing
- Track unwanted material movements
- Detect theft and malpractices
- Zone-based monitoring
- Unauthorized movement alerts
Implementation
The AI Dispatch Tracker was deployed across key areas of the warehouse:
- Integration with existing warehouse management systems
- Real-time dashboards for dispatch supervisors
- Automated reporting of shipment discrepancies
- Visual alerts for wrong and excess shipments
Results
- Drastic Reduction in Wrong Shipments: Wrong and excess shipments were cut down significantly
- Crores of Revenue Saved: The implementation saved crores of revenue for the company
- Improved Customer Trust: Accurate shipments restored customer confidence
- Theft Prevention: Visual fencing techniques identified and prevented malpractices
- 100% Scanning Compliance: No material could leave without proper scanning
Conclusion
The AI-powered dispatch solution transformed this manufacturer's warehouse operations. By implementing AI vision automation, they overcame labor shortage challenges while significantly reducing inventory leakage and shipment errors. The high ROI achieved through crores of saved revenue demonstrates the transformative power of AI in traditional manufacturing environments.