Operational Inefficiencies from Manual Barcode Logging at Amphenol FCI
Problem Statement
Amphenol FCI relied on a fully manual barcode logging system where employees entered item quantities, label IDs, and item numbers by hand. This led to frequent errors, slow processing, and excessive resource consumption. Additionally, the lack of automated backups and data safety mechanisms posed risks to data integrity and operational continuity.
Challenge
Amphenol FCI’s manual barcode entry process led to frequent errors and slow data handling, especially with high volumes. The lack of automated backups increased the risk of data loss, and preparing reports manually was time-consuming and inefficient. Additionally, the system wasn’t scalable for multi-location operations.
Solution Provided
Ideagensys addressed these challenges by building a secure, user-friendly barcode scanning application using Flutter (for both frontend and backend) with SQLite for local data storage. Key elements of the solution included:
- Admin-based login system with operator tracking for accountability
- Real-time scanning with automatic population of key fields such as Label ID, Item Number, and Quantity
- Seamless integration with Zebra barcode scanners
- Instant Excel report generation handling 3–4 lakh+ entries
Key Features
- Real-time barcode scanning with auto-population of fields
- Instant Excel report generation for high-volume data
- Offline data handling with secure local storage
- Admin-based login with operator tracking
- Seamless integration with Zebra barcode scanners
Benefits
Significant Reduction in Manual Effort:
The new solution reduced the need for manual data entry by over 90%. Employees could focus on more critical tasks rather than spending hours inputting repetitive information, leading to better resource allocation.
Accelerated Data Processing:
The digitized barcode system processed entries up to five times faster than the manual approach. Even under high load, it handled data efficiently without slowing down, allowing for quicker turnaround times in inventory processing.
Improved Data Accuracy:
The automated scanning process eliminated the human errors previously common with manual input. The result was near-zero error rates in inventory data, greatly enhancing accuracy in reporting and stock management.
Enhanced Data Security and Backup:
With local storage and offline capabilities, the solution ensured that no data was lost even if connectivity was interrupted. This strengthened data integrity and offered reliable recovery options in case of device or system failures.
Structured Reporting:
Instant generation of well-formatted Excel reports, even with large datasets, meant that data was immediately usable for ERP imports or internal audits. This removed the bottleneck of manual report compilation.
Conclusion
The custom-built barcode scanning system developed by Ideagensys transformed Amphenol FCI’s operations from a manual, error-prone process to a streamlined, accurate, and scalable solution. With dramatic improvements in efficiency, accuracy, and security, the new system laid a solid foundation for digital transformation and operational expansion across the organization.