QR CODE BASED:   TRACK AND TRACE SYSTEM
GTI has implemented the use of a QR code based methodology that will provide accurate and timely decision support for multiple functional within organization, data collection and dissemination of information for each of its facilities, and any future facilities. T has currently implemented it for IOCL’s Servo manufacturing plants across 10 locations in India producing over 10 Crore cans/year. One of the largest in the country. This implementation streamlines work processes, include thorough training for all users of the new technology, and improve the accessibility, timeliness, and accuracy of data. The system should support complete material tracking and also provide IOCL with the ability to take strategic marketing decisions. The solution proposed is to have all the primary packs (cans, buckets) uniquely identified, such that the same can be traced till the end of its sales life span. This is in view to prevent manufacturing errors, combat counterfeit products and improve supply chain efficiencies throughout the organization. The traceability include tracking of primary, secondary and tertiary (Can, Carton, Buckets, pallet) packing level as they are printed with QR codes data matrix code, the solution will make use of the Hardware that will scan/read/ print/mapping and aggregate the QR codes applied at various levels in the packaging. All the scenarios is covered in the plant for packing of products with the appropriate automation for boosting productivity and quality process wherever possible and required. Post plant activities, all the warehouses will be covered with Warehouse Management Light system which will enable scanning carton at the warehouse level and thus providing a point to point scanning of all cartons thus enabling end to end traceability wherever the cartons are getting scanned down the Supply Chain. Warehouse Management System should ensure that the material when dispatched from the plant warehouse/contract manufacturer is tracked and the process at the CIPs and CFAs gets simplified. The system also allows the CIPs to be aware of what material is planned for receipt on any given day. At the retailer and the consumer end an app hosted by GTI has the facility to scan the QR codes on the each’s (SKU) as well as the cartons. IOCL officers should have the feature to scan the carton as well as the SKU. The retailers will also be enabled to scan via the app. On scanning, the user will get the entire history of that particular carton/SKU so as to determine the origin, the warehouse history and also the way it reached the particular place. Also, counterfeit data will be displayed at the scan. This scan can also be used for validating the stock consumption at the distributor end. The app is design in such a way that it will provide real-time feedback regarding authenticity and traceability of the SKUs.
The objectives are many, which are tangible as well as intangible: I. Minimizes counterfeit products in the market
II. Complete end to end track and trace
III. Inventory clarity at all nodes.
IV. Minimizes product/batch mismatch
IV. Minimizes product/batch mismatch
V. Data for analytics for effective decision making
VI. Loyalty programs enables on the barcode platform
VII. Cross State Infiltration minimizes
VIII. Customer peace of mind
IX. Tracking re-use of any SKU / bottle in supply chain
X. Avg. time
Modules of the System
The following modules form part of the system:
1. Printing of QR code at Label Manufacturer
2. Filling and Manufacturing Process including Goods Receipt, Despatch &Internal upkeep
3. CIP/CFA Process
4. Production Management
5. Inventory Management
6. Transit Management
7. Distribution Management
8. Customer Management
Hardware, App&Loyalty Program
Besides the Installation and implementation of Scanners, Handheld Scanners, TIJ Printers, etc. being used at various stages in the plant, Loyalty program enables the features of self-sustaining loyalty program, analytics on the data gathered, user group wise access, Geomapping, authorization of Distributor, retailer, mechanic and consumer based on the UID such as Aadhar no, PAN or any other KYC. Software has the feature to avail the loyalty program by specific consumer. .
The app will give feedback on the unauthenticated codes. The UID that is not available in the database will create a RED flag when scanned, immediately IOCL will be informed by Email. For codes available in the database, the app will give a GREEN go ahead for the first time scan within the area where the codes were supposed to be available. Incase the code is scanned at area where the SKU has no history, then YELLOW displayed on the screen and subsequent action will be taken by intimating IOCL for necessary further investigation. This will also be the case for subsequent scans with different mobile devices.