Wall-to-Wall Inventory Using RGIS Vision for Classic Car Parts Specialist

CHALLENGE

A car parts manufacturer had previously attempted a full inventory internally using a manual process, which proved unsuccessful. The UK warehouse required a complete wall-to-wall stocktake to be completed within a single weekend to avoid disruption to normal operations. With over 10,000 locations and millions of parts, the scale and complexity of the job demanded a robust and highly accurate solution.

The customer faced multiple issues with stock coding:

• Inconsistent part codes from different suppliers.
• Barcode prefixes across both Location IDs and some product codes.
• Frequent mismatches between scanned codes and the product master file.

WHY RGIS?

The customer selected RGIS based on our proven ability to support large-scale inventories using barcode scanning, data validation, and progressive variance reporting, while also being able to integrate their own staff into the counting process.

OUR SOLUTION

RGIS delivered a tailored stocktake plan using RGIS Vision, including:

• Custom Integration: RGIS collaborated with the customer’s IT team to understand their data structures and address mismatched barcodes and code prefixes.
• Vision-Driven Scanning: RGIS Vision scanners recognised non-standard or incomplete part codes by referencing patterns in the master file and applying automated prefix correction where necessary.
• Progressive Variance Monitoring: The warehouse was segmented into three zones, with real-time filters established to monitor variances as the stocktake progressed.
• Collaborative Workforce: To reduce costs and speed up the process, the customer provided 20 staff to assist with counting. RGIS deployed 65 counters, three RTSs for oversight and training, and one Area Manager to lead the operation.
• Locations counted: 10,850 bin locations | Units counted: Over 4,500,000 parts.
• Safety and Equipment: All staff followed strict safety protocols, using hi-vis equipment and working alongside customer-managed lifting platforms for high-level inventory.

RESULTS

• Accuracy: Final shrink was below 1% – better than the customer’s target threshold.
• Customer Satisfaction: The stocktake was completed on time, and the warehouse was fully operational by Monday morning.
• Process Innovation: The project served as the customer’s first successful wall-to-wall inventory using barcode technology.
• Collaboration Success: The partnership approach between RGIS and the car parts manufacturer was essential in meeting deadlines and quality standards.
• Learning: While real-time variance tracking was effective during the count, more structured end-of-day variance control could be considered for future counts.

CONCLUSION

This project was a significant milestone for the car parts manufacturer, demonstrating that large-scale inventory can be delivered accurately and on schedule with RGIS Vision. Although the event was a one-off, with regular PI counts managing day-to-day control, the customer now has confidence in RGIS’s capability for larger projects. With operations across the EU and USA, this success sets the foundation for future collaboration.