Case Study: How Infor Factory Track Enhances Warehouse Management in Manufacturing
In the fast-paced world of manufacturing, efficient warehouse management is the backbone of operational success. Yet, many manufacturers grapple with inefficiencies that drain resources and frustrate customers. Manual inventory tracking, labor-intensive processes, and disconnected systems can lead to costly errors and delays. For instance, Aberdeen Strategy & Research estimated that the average hourly cost of downtime for manufacturing businesses was $260,000 in 2016, a figure that has likely grown with inflation and increased operational complexity. These challenges underscore the need for robust solutions that streamline warehouse operations and integrate seamlessly with enterprise systems.
Enter Infor Factory Track, an end-to-end manufacturing automation solution designed to transform warehouse management. By offering real-time visibility, mobile-enabled workflows, and deep integration with Infor’s ERP platforms like SyteLine/CloudSuite Industrial (CSI), Infor Factory Track empowers manufacturers to optimize inventory, reduce labor costs, and ensure compliance. We specialize in helping businesses leverage Infor solutions to achieve operational excellence. In this article, we’ll explore how Infor Factory Track addresses warehouse management challenges, dive into a real-world case study, and highlight its technical and strategic benefits for manufacturing operations.
Section 1: Understanding Warehouse Management Challenges in Manufacturing
Warehouse management in manufacturing is fraught with challenges that can disrupt production and erode profitability. Many manufacturers rely on outdated, manual processes that lead to inventory discrepancies, slow order fulfillment, and compliance risks. For example, a 2021 survey found that 83% of U.S. warehousing and logistics providers used a warehouse management system (WMS), down from 93% in 2018, suggesting persistent adoption challenges due to cost, complexity, or lack of expertise. These issues manifest in several ways:
- Inventory Inaccuracies: Manual stock counts often result in errors, leading to stockouts or overstocking. This disrupts production schedules and increases carrying costs.
- Labor Inefficiencies: Without automation, workers spend excessive time on repetitive tasks like data entry or locating inventory, reducing overall productivity.
- Lack of Real-Time Data: Disconnected systems prevent managers from accessing up-to-date inventory or labor data, hindering informed decision-making.
- Compliance Risks: For industries like pharmaceuticals or food and beverage, failing to track lot-controlled or serialized items can lead to regulatory penalties.
These challenges directly impact customer satisfaction, as delayed shipments or incorrect orders erode trust. Moreover, they contribute to higher operational costs, with McKinsey reporting that inefficiencies in warehousing can account for 5-10% of total logistics costs. For manufacturers striving to remain competitive, addressing these pain points is critical.
Fortunately, expert guidance can help navigate these complexities. Sama Consulting’s Infor Factory Track consultants specialize in tailoring solutions to streamline warehouse operations, ensuring manufacturers achieve efficiency and compliance.
Want to enhance your warehouse management with Infor Factory Track?
Sama Consulting helps manufacturing enterprises leverage Infor Factory Track to streamline warehouse operations, improve inventory accuracy, and boost overall efficiency.
Section 2: What is Infor Factory Track?
Infor Factory Track is a comprehensive manufacturing automation solution designed to bridge the gap between shop floor operations and enterprise resource planning (ERP) systems. Built on Infor’s Mongoose platform, it offers a modular, mobile-enabled approach to managing warehouse and production processes. Its core modules—Warehouse Mobility, Shop Floor, and Time Track—provide a unified platform for real-time tracking, automation, and integration with Infor’s ERP systems, such as SyteLine/CloudSuite Industrial (CSI) and M3. Here’s a closer look at its capabilities:
- Warehouse Mobility Module: This module enables real-time inventory management using barcode scanning and wireless networks. Operators can perform tasks like receiving, cycle counting, material movement, and issuing directly from handheld devices or tablets. The HTML5-based interface ensures compatibility across devices, minimizing the need for dedicated hardware.
- Shop Floor Module: Designed for work center automation, this module provides a paperless, kiosk-based interface for tracking labor, raw material usage, and finished goods. It supports touchscreen operations, allowing multiple operators to report job progress in real time.
- Time Track Module: This module automates time and attendance tracking, integrating labor data into payroll and cost accounting systems. It reduces manual timesheet errors and ensures accurate labor cost allocation.
- Traceability and Compliance: Infor Factory Track excels at tracking lot-controlled and serialized items, providing visibility across the supply chain. This is critical for industries requiring strict compliance, such as aerospace or medical device manufacturing.
From a technical perspective, Infor Factory Track leverages Infor’s Mongoose platform for rapid application development, enabling customization to meet specific business needs. It integrates seamlessly with Infor’s ERP systems via APIs, ensuring data flows smoothly between the warehouse, shop floor, and back-office systems. For example, real-time inventory updates from the Warehouse Mobility module sync directly with the ERP, eliminating data silos. Additionally, its support for IoT devices enables advanced use cases, such as monitoring equipment performance for predictive maintenance.
The solution’s mobile-first design addresses practical challenges, such as operating in harsh environments like cold storage or noisy production lines. By equipping workers with handheld scanners or tablets, Infor Factory Track reduces the need for fixed computer terminals, saving space and improving accessibility. As noted in Infor’s documentation, the solution minimizes non-compliance risks and provides advanced visibility into serialized items, enabling manufacturers to meet stringent regulatory requirements.
Sama Consulting’s Infor Factory Track consultants bring deep expertise in deploying this solution, ensuring seamless integration and maximum ROI for manufacturers.
Want to enhance your warehouse management with Infor Factory Track?
Sama Consulting helps manufacturing enterprises leverage Infor Factory Track to streamline warehouse operations, improve inventory accuracy, and boost overall efficiency.
Section 3: Case Study – Real-World Implementation of Infor Factory Track
Background: Precision Components Inc.
Precision Components Inc., a fictional mid-sized manufacturer of automotive parts, faced significant warehouse management challenges. With a 50,000-square-foot facility in Ohio, the company struggled with inventory discrepancies, slow order fulfillment, and an upcoming migration from a legacy ERP system to Infor M3. Manual processes, such as paper-based stock counts and disconnected labor tracking, led to frequent errors. Order fulfillment times averaged 48 hours, far exceeding customer expectations for same-day shipping. Additionally, compliance requirements for serialized components added complexity, as the company lacked real-time visibility into inventory.
Frustrated by these inefficiencies, Precision Components partnered with Sama Consulting Inc. to implement Infor Factory Track and optimize their warehouse operations.
Implementation Process
The implementation followed a structured approach, blending technical expertise with operational redesign:
Assessment and Planning:
- Sama Consulting conducted a comprehensive analysis of Precision Components’ warehouse layout and processes, identifying bottlenecks in inventory movement and labor tracking.
- A data cleansing initiative ensured that only accurate inventory and labor data would migrate to Infor M3, reducing errors during the ERP transition.
- Key stakeholders, including warehouse managers and IT staff, collaborated to map current processes and define requirements for Infor Factory Track.
Warehouse Mobility Deployment:
- The Warehouse Mobility module was deployed to enable real-time inventory tracking. Workers were equipped with rugged handheld scanners supporting barcode and RF technology.
- The team optimized the warehouse layout based on inventory movement patterns, reducing travel time for picking and put-away tasks.
- Integration with Infor M3 was configured to sync inventory updates in real time, ensuring accurate stock levels across the ERP system.
Shop Floor and Time Track Integration:
- The Shop Floor module was implemented to replace paper-based job reporting. Kiosk stations with touchscreen interfaces were installed at key work centers, allowing operators to log production data efficiently.
- The Time Track module automated timesheet collection, integrating labor data into Infor M3 for accurate cost accounting.
Training and Testing:
- Sama Consulting provided on-site and remote training for warehouse and shop floor staff, focusing on barcode scanning, mobile device usage, and error reporting.
- User acceptance testing (UAT) validated the system’s functionality, with simulated transactions to ensure reliability under real-world conditions.
Go-Live and Support:
- The system went live in phases, starting with the Warehouse Mobility module, followed by Shop Floor and Time Track.
- Sama Consulting offered post-implementation support, addressing minor issues like device connectivity and user adoption challenges.
Results
The implementation yielded measurable improvements across Precision Components’ operations:
- Picking Productivity: Barcode scanning and optimized warehouse layouts increased picking productivity by 20%, reducing order fulfillment times to under 24 hours.
- Inventory Accuracy: Real-time updates via the Warehouse Mobility module improved inventory accuracy to 98%, eliminating stockouts and reducing excess inventory by 15%.
- Labor Efficiency: The Time Track module reduced timesheet errors by 90%, saving 10 hours per week in administrative tasks.
- Compliance: Enhanced traceability for serialized components ensured compliance with automotive industry standards, avoiding potential penalties.
- ERP Integration: Seamless data flow between Infor Factory Track and Infor M3 improved decision-making, with managers accessing real-time reports on inventory and labor performance.
Qualitatively, the implementation boosted employee morale, as workers appreciated the user-friendly mobile interface and reduced manual tasks. Customers reported higher satisfaction due to faster, more accurate deliveries.
Lessons Learned
The success of Precision Components’ implementation highlights several key lessons:
- Thorough Planning: Comprehensive process mapping and data cleansing were critical to a smooth ERP migration.
- User Training: Investing in staff training ensured high adoption rates and minimized errors.
- Phased Rollout: Implementing modules incrementally reduced disruption and allowed for iterative improvements.
For manufacturers considering Infor Factory Track, partnering with experienced consultants is essential for success. Contact Sama Consulting to explore how we can tailor this solution to your needs.
Want to enhance your warehouse management with Infor Factory Track?
Sama Consulting helps manufacturing enterprises leverage Infor Factory Track to streamline warehouse operations, improve inventory accuracy, and boost overall efficiency.
Section 4: Technical Benefits of Infor Factory Track
Infor Factory Track delivers a suite of technical advantages that transform warehouse management in manufacturing. Its modular design and deep ERP integration make it a powerful tool for addressing operational inefficiencies. Below are the key technical benefits:
Automation of Inventory Operations:
- The Warehouse Mobility module automates tasks like material receiving, cycle counting, and issuing. For example, barcode scanning eliminates manual data entry, reducing errors by up to 90%.
- Real-time inventory updates sync with the ERP system over wireless networks, ensuring accurate stock levels. This is particularly valuable in high-volume environments, where delays in data updates can lead to costly mistakes.
- The module supports advanced inventory strategies like ABC classification and Plan for Every Part (PFEP), optimizing stock levels for high-priority items.
Real-Time Visibility:
- Infor Factory Track provides a unified view of inventory, labor, and production data, accessible via mobile devices or kiosk stations. This enables managers to monitor stock levels, track work-in-progress, and analyze labor costs in real time.
- Integration with IoT devices allows for advanced monitoring, such as tracking equipment performance to predict maintenance needs, reducing downtime by up to 20%.
Labor Management:
- The Time Track module automates time and attendance tracking, capturing data via mobile devices or kiosks. This eliminates manual timesheets, reducing administrative overhead and ensuring accurate labor cost allocation.
- Integration with payroll systems streamlines wage calculations, supporting compliance with labor regulations.
Traceability and Compliance:
- Infor Factory Track excels at tracking lot-controlled and serialized items, providing end-to-end visibility across the supply chain. This is critical for industries like food and beverage or medical devices, where compliance with FDA or ISO standards is mandatory.
- The solution minimizes non-compliance risks by maintaining detailed audit trails, ensuring traceability for regulatory audits.
Scalability and Customization:
- Built on Infor’s Mongoose platform, Infor Factory Track supports rapid customization to meet specific business needs. For example, manufacturers can configure workflows for unique processes like kitting or reverse logistics.
- The HTML5-based interface ensures compatibility with a wide range of devices, from rugged scanners to tablets, reducing hardware costs.
These technical features translate into tangible operational gains, such as reduced cycle times, lower labor costs, and improved customer satisfaction. Sama Consulting Inc. specializes in configuring Infor Factory Track to maximize these benefits, ensuring a tailored solution that aligns with your business goals.
Want to enhance your warehouse management with Infor Factory Track?
Sama Consulting helps manufacturing enterprises leverage Infor Factory Track to streamline warehouse operations, improve inventory accuracy, and boost overall efficiency.
Section 5: Broader Impact on Manufacturing Operations
Infor Factory Track’s impact extends beyond warehouse management, aligning with broader manufacturing trends like lean manufacturing and Industry 4.0. By integrating with Infor’s ERP systems, it supports strategic goals such as cost reduction, operational resilience, and digital transformation. Here’s how:
- Lean Manufacturing: Infor Factory Track supports lean principles by eliminating waste in inventory and labor processes. For example, real-time inventory tracking reduces overstocking, while automated labor reporting minimizes non-value-added tasks. This aligns with McKinsey’s finding that sustainable manufacturing can cut operational costs by 20%.
- Industry 4.0 Alignment: The solution integrates with IoT and predictive analytics, enabling smart factory capabilities. For instance, IoT-enabled equipment monitoring can predict maintenance needs, reducing downtime by up to 20%. Additionally, AI-driven forecasting, supported by Infor’s platform, can reduce inventory errors by 20-50%.
- Customer Satisfaction: Faster order fulfillment and accurate deliveries improve customer experiences. A 2025 survey found that 52% of smaller manufacturers prioritize customer experience, underscoring the importance of reliable warehouse operations.
- Digital Transformation: Infor Factory Track supports digital supply chain initiatives, with 80% of manufacturers expected to invest in digital supply chains by 2027. Its real-time data capabilities enhance visibility, helping manufacturers respond to market volatility.
These benefits position Infor Factory Track as a catalyst for long-term success in a competitive manufacturing landscape. To explore how it can transform your operations, contact Sama Consulting for a tailored consultation.
Conclusion
Infor Factory Track is a game-changer for manufacturers seeking to overcome warehouse management challenges. By automating inventory and labor processes, providing real-time visibility, and integrating seamlessly with Infor’s ERP systems, it delivers measurable improvements in efficiency, compliance, and customer satisfaction. The case study of Precision Components Inc. demonstrates its transformative potential, with a 20% increase in picking productivity and 98% inventory accuracy. However, successful implementation requires careful planning, robust training, and expert guidance.
We empower manufacturers to unlock the full potential of Infor Factory Track. Our experienced consultants tailor solutions to your unique needs, ensuring seamless integration and maximum ROI. Whether you’re struggling with inventory inaccuracies, labor inefficiencies, or ERP migration challenges, Infor Factory Track offers a path to operational excellence. Ready to transform your warehouse management? Contact us today to schedule a consultation and take the first step toward a smarter, more efficient manufacturing operation.
Vilas Pathak
Vilas Pathak is a lead consultant for Factory Track, specializing in operational excellence and real-time shop-floor visibility. He drives deployment and optimization of Factory Track systems to streamline manufacturing workflows, improve traceability, and enhance productivity across production environments.
