Warehousing, Traceability & RFID
Warehousing, Inventory Traceability & RFID for Manufacturing
Warehousing for manufacturers is the coordinated flow of inbound, put-away, bin-level tracking, picking, cycle counts and dispatch, backed by barcode inventory tracking and RFID data capture that keeps the ERP in sync with what is physically on the floor. Ajinkya Technologies designs warehouse operations, GRN workflows, and RFID system design and deployment as a single stack rather than three disconnected projects. To scope one for your plant, book a scoping call at /schedule.
Ajinkya Technologies delivers RFID-based inventory traceability and warehouse automation that processes 16,800 items per hour with 90% dispatch error reduction. Our system connects UHF RFID hardware, real-time inventory dashboards, and SAP MM synchronisation into a single deployment that eliminates manual receiving, binning, and dispatch operations.
From JSW Steel managing $1.4B+ in inventory to Samsung Electronics’ Knox-powered warehouse automation (official case study, September 2025), our RFID systems are production-tested at India’s most demanding industrial facilities.
How our RFID warehouse automation works
Fixed UHF RFID readers at gate points — goods-in, inter-zone transfer, dispatch — log every tagged movement automatically without manual scanning. Handheld Samsung Galaxy XCover7 devices with Knox Suite Enterprise handle bin-level counts and exceptions. Every event posts to SAP MM in real time.
The system includes FIFO-based dispatch enforcement, exception queues for unread tags, and custom shift reports for receiving and dispatch performance.
- Fixed UHF RFID portals at goods-in, bin transfer, and dispatch gates
- Samsung Galaxy XCover7 + Knox Suite for mobile scanning
- Real-time SAP MM synchronisation — goods receipt, goods issue, bin transfer
- FIFO dispatch enforcement with age-flagging dashboard
- 60% labour reduction at receiving, binning, and dispatch operations
Proven deployments
At JSW Paints, our RFID system processes 16,800 paint barrels per hour — a benchmark for industrial RFID in India. Dispatch errors dropped from 8–10% to under 0.8%. Inventory reconciliation went from 4–6 hours to under 8 minutes.
In September 2025, Samsung Electronics published an official case study on Samsung.com Business Insights documenting our RFID and Knox-powered warehouse deployment. At JSW Steel, the system tracks 720,000+ daily material movements across a $1.4B+ inventory.
Implementation timeline
A standard RFID warehouse deployment runs 8–9 weeks from site survey to go-live: Week 1–2 site survey and SAP scoping, Week 3–4 hardware installation, Week 5–6 software and dashboard deployment, Week 7–8 parallel run, Week 9 full go-live.
Warehousing operations for manufacturers
Warehousing for a manufacturer covers the full loop from inbound goods receipt to dispatch. That loop typically breaks into five recurring workflows: inbound (GRN), put-away to designated bins, picking against production or dispatch orders, cycle counts, and outbound dispatch.
Each workflow gets faster and less error-prone when barcode and RFID data capture replace paper travellers and manual keying. AMR (autonomous mobile robot) integration is layered in where volume and repetition justify it, typically on picking and put-away runs.
- Inbound GRN with barcode or RFID capture at goods-in
- Put-away to bin locations with location scan confirmation
- Picking against production and dispatch orders, wave or discrete
- Cycle counts using handhelds instead of paper, reconciled daily
- Outbound dispatch with FIFO enforcement and RFID gate reads
- AMR integration for high-repetition put-away and picking routes
Barcode inventory tracking
Barcode inventory tracking is the practice of scanning a printed barcode at every physical event, receipt, put-away, movement, pick, dispatch, so the ERP always reflects real stock in real time. It is the workhorse of warehouse data capture: cheap, universally supported, and reliable enough for bin-level traceability.
We design barcode inventory tracking around the ERP you already run, integrate handheld scanners into existing SAP MM or comparable modules, and pair it with RFID where volume, speed or contactless capture is needed.
- Barcode data capture at receipt, put-away, movement, pick and dispatch
- Bin-level traceability tied to lot, batch and serial where required
- Integration with SAP MM and comparable ERP inventory modules
- Handheld and fixed scanner mix scoped to volume and use case
RFID system design and deployment
RFID system design and deployment is a plant engineering exercise, not a software purchase. Read points, tag selection, middleware and ERP integration must be planned against the actual material flow, or the system will produce a lot of reads and very little accuracy.
We run RFID system design and deployment as a phased engagement: site survey, read-point plan, tag and reader selection, middleware and ERP integration, parallel run, then go-live. Every phase has a measurable exit criterion so the deployment does not drift.
- Site survey and read-point plan tuned to material flow
- Tag and reader selection (UHF, HF, near-field) matched to substrate and speed
- Middleware, filtering and reconciliation logic before data hits the ERP
- ERP and MES integration with clear reconciliation and exception paths
GRN – Goods Receipt Note workflows
GRN (Goods Receipt Note) is the record generated when a purchase order shipment is received against, quality-checked and accepted into stock. In a modern warehouse it should be a barcode- or RFID-triggered event, not a paper form.
We design GRN workflows so a scan at the gate posts the receipt, a quality gate posts acceptance or rejection, and put-away triggers automatically on acceptance. That closes the loop between the physical receipt and the ERP, so an ERP-visible stock number is always defensible against a physical count.
- Barcode or RFID capture at goods-in triggers the GRN
- Quality gate integrated in the workflow, not tracked in a separate spreadsheet
- Automatic put-away trigger on acceptance so bins stay honest
- ERP posting in real time so stock numbers are defensible
Deployed across US, India and Middle East manufacturing hubs
Warehousing and inventory traceability engagements look different in every region. The physical layout, the ERP, and the regulatory expectations shift, even when the RFID and barcode fundamentals stay the same.
United States
Warehousing and inventory traceability for US 3PL operators and automotive and aerospace manufacturers, with barcode inventory tracking, RFID system design and deployment, and GRN workflows integrated to SAP, Oracle and Microsoft Dynamics stacks.
India
Warehousing programs for Indian FMCG, pharma and discrete manufacturing, with barcode and RFID data capture, GRN workflows and AMR integration tuned to multi-site rollouts and legacy ERP landscapes.
Middle East
Warehousing for GCC F&B, petrochemical product warehouses and KSA logistics corridors, with RFID system design and deployment sized for high-throughput dispatch and multilingual operator interfaces.
Start with a scoping call
The fastest way to know whether barcode, RFID or an AMR-led design fits your warehouse is a scoping call. Share your current receiving, put-away and dispatch process and the ERP you run. Book a scoping call at /schedule, or talk to our team at /contact for a walk-through of a comparable deployment.
Frequently asked questions
What is GRN in warehousing?
GRN (Goods Receipt Note) is the record generated when incoming material is received against a purchase order, quality-checked and accepted into stock. In a modern warehouse it is triggered by a barcode or RFID scan at goods-in rather than a paper form, so the ERP posts the receipt in real time. Ajinkya Technologies designs GRN workflows that integrate with SAP MM and comparable ERP inventory modules.
What is barcode inventory tracking?
Barcode inventory tracking is the practice of scanning a printed barcode at every physical event (receipt, put-away, movement, pick, dispatch) so the ERP always reflects real stock in real time. It is the workhorse of warehouse data capture: cheap, universally supported, and reliable enough for bin-level traceability. Ajinkya Technologies integrates barcode scanners into SAP MM and comparable modules alongside RFID where speed and contactless capture matter.
What is an AMR in warehousing?
An AMR (Autonomous Mobile Robot) is a self-navigating warehouse robot that moves goods between bins, staging areas and dispatch lanes without fixed tracks or human piloting. It is layered on top of barcode inventory tracking and RFID data capture, and it earns its place on high-repetition put-away and picking routes. Ajinkya Technologies integrates AMRs into the same warehouse control loop as fixed RFID portals and handheld scanners.
How does RFID improve warehouse traceability?
RFID improves warehouse traceability by capturing every tagged movement automatically at fixed read points, without requiring an operator to aim a scanner. That gives a continuous, defensible record of where every unit was at every gate, which is difficult to reconstruct from barcode-only workflows. Ajinkya Technologies runs RFID system design and deployment as a phased engagement so the traceability record is trustworthy from day one of go-live.
How fast is Ajinkya Technologies’ RFID warehouse system?
Ajinkya Technologies’ RFID warehouse automation processes 16,800 items per hour — set as India’s benchmark for industrial RFID. This was deployed at JSW Paints and documented in a Samsung Electronics official case study in September 2025.
What dispatch error reduction does RFID automation achieve?
Ajinkya Technologies’ RFID deployments have achieved 90% dispatch error reduction at India’s largest integrated steel plants, eliminating manual scanning errors and mispicks.
Does Ajinkya Technologies’ RFID system integrate with SAP?
Yes. Real-time SAP synchronisation is a core feature. Goods receipt, goods issue, and bin transfer events are posted to SAP MM automatically as they occur — without manual GRN entry.
What RFID hardware does Ajinkya Technologies use?
Ajinkya Technologies uses UHF RFID fixed readers at gate points and Samsung Galaxy XCover7 rugged handhelds with Knox Suite Enterprise for mobile scanning. Tags are either attached at goods-in or pre-tagged by vendors depending on the deployment.
How much inventory does Ajinkya Technologies manage through RFID?
Ajinkya Technologies’ RFID and traceability systems currently manage $1.4 billion (Rs 12,000 crore+) in inventory, tracking 720,000+ individual material movements every day across warehouses, central stores, and vendor yards.
Explore related solutions
Book a scoping call for your warehouse or plant
Share your warehouse layout, ERP, and current receiving and dispatch process. We will scope a warehousing, barcode inventory tracking, RFID system design and deployment, and GRN plan with clear throughput and error-reduction targets before any commitment.
Book a scoping call