Manufacturer Improves Product Traceability
Overhead Sign Installation and New WMS Help Brembo Improve Inventory Management
Brembo is a world leader in the manufacture of automotive brake systems, especially for high-performance cars and motorcycles. Headquartered in Italy, the company operates in 14 countries and employs more than 11,000 people. Its North American headquarters is in Plymouth, Michigan, near Detroit.
The Challenge: Poor Inventory Traceability
Brembo lacked advanced inventory management capabilities. The company had been using a chipboard floor system to manually identify finished goods and parts in its Michigan facility. This process was time consuming and inefficient, and made product traceability a challenge.
“It worked OK, but it had its shortcomings,” said Dustin Youtsey, Brembo’s continuous improvement supervisor. “Without the right tools, we had limited visibility into our product inventory and location identification. Our warehouse workers were wasting time trying to manually find product.”
“We opted to have ID Label professionally install the signs for us, which was a great decision. They have a sophisticated tension cabling system that firmly holds the signage in place.”
– Dustin Youtsey, Brembo
The Solution: WMS and Professionally Installed Overhead Signs
Brembo made the strategic decision to invest in warehouse management software (WMS) and a barcoding system to improve traceability and operational efficiencies.
“We don’t have much racking,” Youtsey said. “We have 250 staging lanes in our finished goods area where we inventory our products when they come off the line.”
The new system meant Brembo required barcoded overhead bulk storage signs to properly identify its lanes and manage inventory in the new WMS.
ID Label Turnkey Installation
Youtsey contacted ID Label. “My original intention was to purchase the signs and have our maintenance crew hang them from the ceiling,” he said. “But ID Label provided an alternate recommendation that made a lot of sense.”
In many warehouse facilities like Brembo’s, air circulation must be considered for overhead sign applications. Signs that are simply suspended on chains or wires are likely to swing back and forth due to the air flow. This can make it difficult and time consuming for workers to accurately scan a barcode that might be 20-50 feet above their lift truck.
“We opted to have ID Label professionally install the signs for us, which was a great decision,” Youtsey said. “They have a sophisticated tension cabling system that firmly holds the signage in place.”
He also recognized some of the challenges his maintenance crew would have faced had they done the installation themselves. “Our team didn’t have the expertise, equipment or additional staff to tackle a project like this,” he said. “ID Label saved us a lot of time and effort, and we have the confidence of knowing the job was done right.”
“ID Label had all those signs hung and installed in less than two days. Who knows how long it would have taken us and if it would have turned out the way we wanted?”
– Dustin Youtsey, Brembo
Seamless Process
ID Label designed 16” x 11” angled signs on PVC material. The sequential barcode images were printed on specialized retroreflective material for fast and accurate long-range scanning.
“ID Label was great to work with, start to finish,” Youtsey said. “It was a seamless process. They took the time to understand my operating environment and application to provide a solution, not just a price quote,” he said.
Rethink DIY
Youtsey recommended that others in a similar situation think twice before attempting a DIY warehouse installation.
“You could tell that ID Label’s installation team knew exactly what they were doing,” he said. “They had all those signs hung and installed in less than two days. Who knows how long it would have taken us and if it would have turned out the way we wanted?”
For Brembo, the overall project means improved processes, smoother work flows and greater efficiencies.
Youtsey added: “Now we have up-to-the-minute visibility into our inventory and our workers know exact locations for quickly placing or picking products.”
The ID Label Advantage
New warehouse project? Consult with ID Label to understand your options. We’re passionate about helping our clients find the best solutions to keep their businesses moving forward.
ID Label’s warehousing products – from rack and LPN labels to signs and installation services – have been tested and used by operations around the globe for more than 25 years. That’s extensive experience and knowledge we can bring to your specific requirements.
Interested in learning more? Contact us today.