Kapal Api - Pallet Barcode System & Real Time Warehouse Visibility

Boostech helped Kapal Api drastically reduce inter-warehouse shipment variances through the implementation of a pallet barcode system integrated with Oracle. This solution provides real-time visibility from loading, staging, to receiving, while simplifying end-of-day reconciliation from ±1 hour to just ±5 minutes. As a result, delivery deviations dropped from ~1,000 boxes/month to only 5–10 boxes/month.

Overview

• Client: Kapal Api

• Scope: Warehouse & inter warehouse transfer (palletization, tracking, reconciliation)

• Key Technologies: Pallet barcode (1D/2D), mobile scanning (Android), real time dashboard, role based tasking, Oracle integration (inbound/outbound & data posting)

• Main Objective: Reduce shipment discrepancies, accelerate checking & approval, and improve accuracy and transparency between warehouses

Challenges

• High Shipment Variance: Deviations reached ~1,000 boxes/month during inter-warehouse transfers.

• Limited Item Visibility: Difficult to track pallets in staging before reaching the destination warehouse.

• Time-Consuming Reconciliation: Manual end of day “totals” took ±1 hour.

• Cross-Role Coordination: Operators, checkers, and supervisors struggled to see progress and workload in a unified view.

• System Integration: Operational data needed to sync with Oracle without adding user complexity.

Our Solution

1. Pallet Barcode & Mobile Scanning

   • Each pallet is assigned a unique barcode containing SKU, quantity (boxes), origin & destination, and status.

   • Android mobile app scans pallets during picking, loading, staging, and receiving to track end to end movement.

2. Real Time Tracking & Staging Visibility

   • Live dashboard shows pallet locations (loading → staging → inbound), estimated arrival, and expected box count.

   • Destination warehouses can anticipate incoming boxes; origin warehouses monitor receiving status in real time.

3. Role Based Tasking & Workflow Approval

   • Operators receive structured tasks specifying what to send, where, and when.

   • Supervisors monitor progress, perform spot checks, and approve quickly via the dashboard.

4. Automated Reconciliation (“Totalan” in 5 Minutes)

   • System matches planned vs. actual counts by pallet & box.

   • Exception list (miss scan, short/over, wrong destination) appears automatically for quick action.

5. Seamless Oracle Integration

   • Goods movement data is posted to Oracle in real time or near real time with safe queuing (retry & logging).

   • Master data mapping (SKU, location, documents) & quantity validation prevents duplication or inconsistency.

Result

• Extreme Deviation Reduction: ~1,000 boxes/month ⇒ 5-10 boxes/month.

• Lightning-Fast Reconciliation: End of day totals cut from ±60 minutes ⇒ ±5 minutes.

• Full Transparency: Both warehouses see planned vs. received box counts in real time.

• Operator Productivity Improved: Clear tasks, measurable progress, and fewer scanning errors via validation.

• Enhanced Supervisor Control: Live monitoring, fast approvals, and clean audit trails.

• Unified Data in Oracle: Accurate transactions, reliable inventory, and movement reporting.