95.2% → 99.6%
Stock Accuracy
0 next quarter
Short Shipments
Eliminated
Daily SAP Data Entry
1,800+
SKUs Managed
The Challenge
The manufacturer operates an in-house finished goods and spare parts warehouse storing over 1,800 SKUs — extinguisher cylinders, valve assemblies, propellant cartridges, and service kits spanning multiple pressure ratings and certifications. Inventory was managed in Excel, updated manually after each despatch run. Stock counts regularly showed discrepancies of 3–5%, leading to either short shipments on urgent site orders or overstock write-offs on slow-moving variants. More critically, regulatory traceability requirements for fire suppression equipment meant that shipment records needed to show which certified batch of extinguisher bodies and propellant charges were sent to each installation site — a requirement that paper-based despatch notes could not reliably satisfy.
The Solution
Deployed Warehouse Management System and Product Traceability on MACHHUB. All finished goods and spare parts were given bin locations with barcode labels. Inbound put-away, picking, and despatch are now barcode-guided, with each movement recorded against the relevant production batch and certification lot. Outbound despatch records automatically include the serial numbers, batch codes, and certification references of all items shipped, providing a complete chain of custody to each customer site. MACHHUB was integrated with the customer's SAP ERP via MQTT, with MACHHUB publishing warehouse events — goods receipts, despatch confirmations, and cycle count results — to a message broker that SAP subscribes to, synchronising stock levels in real time, automatically posting goods receipts against SAP purchase orders upon inbound confirmation, creating outbound delivery documents when customer POs are picked and despatched, and pushing cycle count results directly into SAP inventory postings — eliminating the need for manual data re-entry between the warehouse and finance systems.
The Result
Stock accuracy improved from 95.2% to 99.6% within the first 45 days. Short shipment incidents on urgent site orders dropped to zero in the following quarter. Regulatory despatch documentation — previously assembled manually from multiple paper sources — is now generated automatically at the point of despatch. The SAP integration eliminated an estimated 2.5 hours of daily manual data entry previously performed by the admin team to keep SAP stock balances, PO statuses, and delivery records in sync with the physical warehouse.
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