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Smart Asset Tracking with RFID: Optimizing Bin & Pallet Management at Toyota TTBIL

Automotive Manufacturing & Logistics

Industry

4-6 Months

Duration

Mobile (Android handhelds with RFID readers)

Platform

Mobile UX & Development, RFID Integration, Secure Data Sync, Rollout Support

Services

Reduced asset losses, faster bin tracking, and improved inventory accuracy

Impact Metrics

Overview of the Project

Toyota TT Bharat Integrated Logistics (TTBIL) faced recurring challenges in monitoring bins and pallets across inbound and outbound operations. Impiger developed a custom mobile app powered by RFID scanning to simplify tracking, prevent mismatches, and reduce missing assets. The app provided real-time visibility while supporting offline usage during warehouse operations.

Challenges

  1. Missing and mismatched bins during inbound/outbound handling.
  2. Manual reconciliation slowed down dispatch cycles.
  3. Lack of real-time visibility into asset movement.
  4. Dependency on paper logs created errors in audits.

Approach

  1. Built a mobile-first asset tracking app with RFID tag integration.
  2. Enabled inbound and outbound scanning for faster reconciliation.
  3. Designed offline-first functionality to handle low-connectivity warehouses.
  4. Added alerts for mismatches and missing bins.
  5. Integrated data sync with central ERP for accurate reporting.

Key Components / Integrations

RFID Tagging & Scanning

Each bin/pallet assigned a unique RFID for quick reads.

Inbound & Outbound Checkpoints

Scan assets at entry/exit for real-time updates.

Mismatch & Missing Alerts

Automatic detection of discrepancies.

Search & Audit Mode

Simplified lookup for bins during inspections.

ERP Integration

Seamless sync with backend systems for inventory accuracy.

Accelerators / IP Used

Pre-built RFID scanning modules and offline-sync patterns were reused to accelerate development.

Outcomes / Impact

  1. Reduced asset loss through accurate RFID-based tracking.
  2. Faster inbound/outbound handling with instant scans.
  3. Improved audit accuracy with digital trails.
  4. Lower manual effort as paper-based checks were eliminated.
  5. Better visibility into asset flow across warehouses.

Before

  1. Manual logs for bins and pallets
  2. Frequent mismatches in dispatch
  3. Missing assets hard to trace
  4. No digital record for audits

After

  1. RFID-based mobile scanning
  2. Automated inbound/outbound reconciliation
  3. Alerts for mismatches and missing bins
  4. Real-time sync with ERP and audit-ready logs

What’s Next

Future roadmap includes IoT sensor integration, predictive maintenance alerts, and dashboard analytics for asset utilization across the supply chain.

Like to know more? Talk to our experts who worked on the project.

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