Barcode verification gate,
zero-defect shipment.
Implemented at PMI's Torbalı (İzmir) factory, the Automatic Shipment Barcode Verification System scans pallet labels at the shipment exit, verifies them against shipment orders, and updates SAP-WMS.
Fully automated control at shipment exits
PMI's Torbalı (İzmir) factory is a cigarette manufacturing facility. The produced items are shipped on a pallet basis via exit ramps during the shipment process.
The project was implemented to automate the pallet verification and shipment order matching process at the shipment exit.
Shipment errors and control difficulties
Checking pallets manually against correct work orders at shipment ramps caused delays and increased shipment error risks.
- 01Shipment Error RiskThe risk of incomplete or incorrect barcode products being shipped without detection.
- 02Manual MatchingOperational inefficiency caused by manually matching pallet labels with shipment work orders.
- 03WMS SynchronizationInability to process pallets exiting from ramps into the WMS system instantly and automatically.
Barcode Gate System & Automated Verification
The barcode gate system installed at the exit ramp automatically reads all pallet labels. The system automatically retrieves shipment orders from SAP-WMS, compares them with pallet labels, and writes data to WMS on match.
Work Order Integration
Work orders belonging to the shipment plan are automatically loaded from the SAP-WMS system.
Ramp Barcode Scanning
The Barcode Gate on the exit ramp automatically reads all pallet labels passing over it.
Match & Verification
Pallet labels are compared with shipment orders to instantly query content accuracy.
WMS Confirmation
Matched pallet barcodes and the shipment number are instantly sent to the SAP-WMS system.
Industrial scanners and SCADA verification
Industrial Barcode Readers
Industrial scanners that read pallet barcodes on the fly at exit ramps without errors.
PLC field automation
PLC system managing pallet transits, sensors, and gate flow at the ramp.
SCADA application with C#
SCADA software managing matching logic, operator alert screens, and system data integration.
WMS data layer
Integration interface where matched pallet barcodes and shipment numbers are pushed to the WMS system.
Operator Alert System
Control mechanism providing visual/audible warnings to the operator in case of mismatched or incorrect labels.
SAP ERP integration
SAP connection that enables the system to automatically retrieve shipment work orders.
SAP-WMS Integration
The automatic shipment barcode verification system runs with bi-directional and real-time integration with PMI's SAP-WMS infrastructure; data is verified independent of the operator.
Shipment work orders in the SAP-WMS system are automatically pulled into the system, ready for verification.
Verified pallet barcodes and associated shipment numbers are written back to the SAP-WMS system in real time.
100% Verified automated shipment
Automated pallet verification
100% automated pallet verification is achieved at the shipment exit, eliminating the need for manual checks.
Zero shipment errors
Shipment of products with missing, wrong, or incorrect barcodes from shipment ramps is completely prevented.
Operator warnings
Shipment operations are secured with an instant warning mechanism when an incorrect pallet is detected.
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