The implementation of a real-time RFID-based inventory management system significantly improved operational efficiency at a warehouse previously reliant on manual pallet tracking and verbal coordination. The old system caused delays, overworked staff, and poor resource utilization. With RFID integration, forklift operators now retrieve pallets directly from digital production plans, eliminating manual searches and streamlining communication. An ExtendSim model and Multi-Criteria Decision-Making Analysis (MCDM) helped select optimal RFID components, balancing performance and cost.
The results were striking: operator utilization dropped from 68% to 15%, and average cycle time was reduced by 44%. These improvements align with Industry 4.0 principles, enhancing traceability, visibility, and data-driven decision-making. The project demonstrates how digital transformation can lead to smarter, faster, and more reliable inventory processes, better equipping operations to meet modern business demands.