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Case Studies

Case Studies

Commercial Field Service



The Problem:  Manual scheduling of 152 mobile service technicians and weekly shipments of paper workorders caused inaccuracies and severe billing delays, customer frustration and enormous weekly shipping costs. Lack of rugged mobile devices and no unified corporate voice and data plans caused poor or no communication with field workers, erratic scheduling and disorganized routes.

The Solution: A comprehensive solution to automate field service processes, eradicate manual paperwork, reduce or eliminate weekly shipping charges and integrate voice and data plans to put all field workers on the same network with immediate access to essential corporate data. Centralized device management to allow corporate IT to manage, control and troubleshoot all devices in the field from headquarters location.

The Results: Immediate reduction of weekly shipping charges led to over $600,000 in annual savings alone, along with dramatic billing improvements and fleet fuel savings of over 22,000 gallons annually. 

Ski Resort


The Problem:  Busy Ski Camp needed accurate way to track and locate over 1,000 children participating in various camp activities across a 1,000-acre campus, plus improve billing timeliness and accuracy, all within a 30-day window.

The Solution:  Mobile solution deployed to work in the harsh outdoor environment of a Vermont winter. Instructors to scan and associate children with various classes, then synch to accounting system for accurate and immediate billing.

The Results:  Significant improvements in billing accuracy and timeliness, and invaluable tracking capabilities for children participating in camps gives resort a competitive edge.


Retail Pharmacy/Healthcare


The Problem:  LimitBar Code ID Systems White Paper Pharmacy/Healthcare Industryed document storage space to comply with federal mandates, insufficient countertop space, expensive document scanning technologies and the need for bar code scanning causing reduced productivity and efficiency.

The Solution:  Fast electronic image capture and small file storage of paper prescriptions, with bar code scanning capabilities in one device. Accurate, cost-effective, integrated printing, efficient power management and maximum use of limited physical space.

The Results:  Major pharmacy reduced the scan time of letter-sized prescriptions by 900% and gained up to 15 hours per week in labor hours.



The Problem:  Hand labeling of case cartons with preprinted labels was expensive, time-consuming and inefficent. Hand-stamped variable data resulted in illegible or misaligned, inconsistent text.

The Solution:  Take control of carton labeling on eight production lines to increase worker productivity and eliminate numerous issues associated with preprinted labels and incorporate SAP-generated, variable data.

The Results:  Integrated production line with rugged, performance-line printers captured host data, reduced inventory costs, decreased man-hours and increased line-worker efficiency.






The Problem:  Inefficient centralized printing station for hundreds of inbound pallets into logistics warehouse caused inefficient workers, mis-labeled pallets, mis-shipments or lost items.

The Solution:  Streamline receipt of products, pallet labeling and product put-away throughout 450,000 square foot facility with mobile printing solution for point-of-receipt labeling.

The Results:  Complete mobile printing solution increased operator efficiencies, improved material handling times, decreased rerouting problems and virtually eliminated mis-labeled pallets.




The Problem:  Manual identification, tracking and distribution of all toys and food certificates for gift bags caused extensive delays, numerous interruptions and obstructions in the Christmas distribution program.

The Solution:  Label all gift bags as assembled with bar codes and complete cycle count of all bags prior to distribution day. Establish automated check-out system to track bags as given to proper recipients.

The Results:  BarCode Solution Systems donated time, equipment and a custom tracking application to streamline the Christmas Distribution Program. Automated procedures resulted in smooth, efficient and organized distribution that ran ahead of schedule.


Airline Parts Distribution


The Problem:  Manual inventory handling with no scanning system caused shipping and receiving inaccuracies, lengthy put-away times, inventory discrepancies and labor increases.

The Solution:  Wireless LAN configuration and installation for real-time connectivity to UNIX inventory system, mobile computers and shelf- and floor-marking location labels for accurate inventory picking and put-away.

The Results:  Comprehensive wireless data collection system returned significant improvements in inventory accuracy and reconciliation, reductions in labor costs and elimination of emergency product replacement shipments.


Automotive Compliance

The Problem:  OEM automotive supplier required to meet GM compliance labeling standards in seven US manufacturing facilities. Involved replacing obsolete printing systems to accommodate 2-D bar code technolog and establishing failsafe redundancies to allow label generation during network or host outages.

The Solution:  Integrate multiple label printing stations at 7 manufacturing facilities with a central AS-400 network, create data distribution program on NT server to filter data to appropriate facilities and feed labeling system, and generate compliant GM1724 labels, printable during server outages.

The Results:  All required facilities met the GM-mandated deadlines and can print compliant GM1724 and/or other standardized label formats easily and automatically. Resources throughout manufacturing facilites are maximized with failsafe systems to allow uninterrupted business flow, even during system downtime.


International Data Collection Solution


The Problem:  Existing proprietary system was cumbersome and obsolete. Could not handle more than one warehouse function at a time, could not produce shipping manifests, was not bilingual. Older handheld terminals subject to frequent malfunction and break downs.

The Solution:  Bilingual data collection system for finished goods put-away, raw material receiving, shipping and inventory, with full reporting, to run all warehouse functions simultaneously.

The Results:  Open-source solution replaced and expanded existing inventory management systems at pilot facilities, dramatically increasing warehouse productivity and labor efficiency. Complete training of Coats IT staff for system-wide roll-out at all 22 facilities worldwide.


Industrial Print & Apply


The Problem:  Unreliable printers, breakdowns, hand labeling and print quality issues caused conveyor-line backups, manual intervention and false reads by fixed-position scanners, resulting in decreased productivity in manufacturing facility running 3 daily shifts, 7 days per week.

The Solution:  Replaced aging and obsolete printers and homegrown applicator systems with automated print-and-apply labelers integrated into conveyor lines. PLCs (Primary Logic Controllers) would stop the lines for accurate placement of labels in the required, small-tolerance space, then signal to start the lines again.

The Results:  Immediate and improved productivity results were realized after new solution was in place. Scanning errors and printer downtime/maintenance were virtually eliminated, as was manual intervention on the conveyor lines.


Automotive Aftermarket

The Problem:  Outdated software, frequent system lock-ups, disconnected work stations and difficulty in locating label formats caused this leading filter manufacturer extensive down time, slow production lines and inability to connect to new ERP system. Multiple vendors were pointing fingers at others for the causes of the problems and weren't supplying solutions.

The Solution:  As a single-vendor resource for the entire project, BarCode Solution Systems provided all components of a demanding new system, including multi-platform integration that was stable, fully-redundant and fault tolerant; a database-driven system with re-directional output, job queuing capabilities, data validation and input restriction; centralized administration of database and label formats; verification of multiple symbologies; and overall improvements of system performance.

The Results:  Significant and measurable improvements with a stable, intuitive, easy-to-use solution that surpassed production requirements by 300%, and has been installed in seven of the company's manufacturing facilities throughout the country.