Barcode Labeling System Overhaul for Finished Goods (12+ Year Project)
Management Consulting • Training & Research • Supply Chain • Agile • WMS/ERP
Transforming Operations. Delivering Results. Empowering People.
Alexandria, Virginia | DC Metro Region | National
Barcode Labeling System Overhaul for Finished Goods
Project Background and Challenge:
Significant customer dissatisfaction resulted from improperly labeled finished goods, impacting automated warehousing operations and eroding trust. I was assigned to remediate these deficiencies.
Analysis:
Root causes included proprietary print & apply fixtures, obsolete DOS-based software, inconsistent production line quality checks, and disparate supplier sourcing for applicators and consumables.
Solutions:
In partnership with engineering, I redesigned system hardware and connectivity, specified new PLC-managed central containers, and transitioned labeling software to modern Windows platforms via RFPs. Print & apply units were standardized, and barcode creation software was unified.
Project Management:
Upon securing funding, I managed a multidisciplinary team through implementation. Communication with senior leadership and key stakeholders was maintained throughout.
Outcomes:
The re-engineered system delivered measurable cost savings—up to 40% on applicators—and improved accuracy in product delivery, prompting executive authorization to extend the solution to other plants. This project was incorporated into my ongoing portfolio.