Transforming Inventory Data for an Electrical Equipment Manufacturer

Industry

Manufacturing

Challenge

Eaton, a global leader in power management solutions, needed to validate and enrich the dimensional and weight data for thousands of inventory items in its Missouri facility. Outdated data collection tools and incomplete WMS data were affecting inventory accuracy and delaying reliable decision-making.

Results

ALLSERV processed 2,026 items, achieving a 99% Data Accuracy rate. This led to improved warehouse space utilization, a higher throughput of 150 items/hour, and significant reductions in workarounds, over-ordering, and material waste.

Services

Inventory Counting Services

www.eaton.com/

2,026+

Items processed

150

items/hour Throughput Achieved

99%

Data Accuracy

Partnering with ALLSERV delivered the high-quality data accuracy we needed to drive significant operational improvements across our facility. The entire engagement was seamless.

Chief Operations Officer

Eaton

About

Eaton is a global leader in power management solutions, dedicated to improving the quality of life and the environment through the use of power management technologies and services. The company provides a comprehensive range of electrical, hydraulic, and mechanical power solutions to meet the growing demand for reliable, efficient, and sustainable power.

The Challenge

Before engaging ALLSERV, Eaton faced a critical challenge in its Missouri facility's warehouse operations. The existing Warehouse Management System (WMS) data was either incomplete or inaccurate in terms of the dimensional and weight data for thousands of inventory items. This core data deficiency was severely undermining inventory accuracy and the affected the ability to make reliable operational decisions regarding slotting and racking. Furthermore, the reliance on outdated data capture tools (Cubiscan 110 models) could not handle small components effectively, creating a queue and processing delay bottleneck that needed costly temporary manual workarounds.

The Solution

Eaton selected ALLSERV to validate and enrich inventory data. ALLSERV deployed a team of data-capture experts and utilized its tools and expertise to rapidly capture accurate data. The team utilized the facility's single Cubiscan 325 Model as the core data capture tool, which was a significant upgrade from the older Cubiscan 110s. The team's approach was to accelerate processing and break the bottleneck by manually capturing dimensional and weight details for specific small parts that could not be easily measured by the single unit.

The ALLSERV team performed a full cycle count and rigorously cross-validated all new data against Eaton's WMS records, guaranteeing accuracy before system updates. This was crucial for establishing a solid foundation of reliable information.

The Results

ALLSERV's engagement yielded significant, measurable results for Eaton's inventory and warehouse operations:

2,026 items were processed, providing the reliable dimensional data leading to better use of warehouse space and better decision making.
A 99% Data Accuracy rate was achieved for correct weight and dimension data, which reduced errors in procurement calculations, cutting down on over-ordering and material waste.
A 150 items/hour Throughput was achieved, improving the total volume of inventory processed.

The Recommendations

ALLSERV recommended replacing all outdated Cubiscan 110 models with newer models to significantly improve efficiency in capturing the dimensions and weights of small components.
For tracking, ALLSERV also recommended the development of a production tracker to provide daily updates on data capture progress, sustaining a culture of high inventory accuracy.