Inward Barcode & FIFO Tracking Integrated with SAP S/4HANA

Victor Reinz (Dana Limited brand) specializes in engine and exhaust sealing solutions—cylinder-head gaskets, oil seals, valve stem seals, intake/exhaust manifold gaskets, and turbocharger mounting kits. 

Victor Reinz India sought to streamline its warehouse inbound and issue processes with a barcode-driven inbound system and FIFO tracking, tightly integrated with SAP S/4HANA Public Cloud.   

• Manual touchpoints during inbound and issue were slowing operations and      introducing errors. 
• Limited package-level traceability made FIFO enforcement difficult across      put-away and picking. 
• Fragmented data flow between handheld activities and SAP S/4HANA caused      reconciliation and reporting delays.  

Mazeworks implemented a centralized web applicationwith an Android handheld scanner app (V‑CONNECT‑2), QR/label printing, and a SAP integration module. The solution covers both Material Inward and Material Issue/Reservation & Picking processes, with FIFO alerts and validations to drive compliant execution. 

Key Components

• Web Application (central server) + Mobile app (Android handhelds) for scanning workflows. 
• GRN QR code generation and package label printing for granular tracking. 
• SAP Integration Agent supporting data read/post between the warehouse app and S/4HANA Public Cloud. 
• FIFO alerting and location-aware put-away/picking to enforce sequence. 
• Integration Options:  The design supports SAP data exchange via SAP Gateway/PI/PO or FTP-based sync, with SAP-side logic for fetching/posting master and transactional data. 

How It Works

1) Inbound (Gate to Put‑Away)

1. Gate Entry: Capture transporter details and number of packages; post Gate      Entry (GE)
2. PO Retrieval: Pull PO details (vendor, items, quantities).
3. GRN & Batch: Create GRN and batch; fetch GRN details.
4. Split & Label: Split received quantities across packages and print package labels (QR).
5. Put‑Away: Scan location + package to complete system-guided storage; movement      posting recorded. 

2) Reservation, Picking & Issue (FIFO)

1. Reservation: Read reservation details with quantities from SAP. 
2. Picklist: Create picklist from reservation and route to handheld device. 
3. Guided Picking: Scan package labels by material serial/package at system-suggested locations with FIFO enforcement. 
4. Close & Post: Complete scanning, close picklist, and perform transfer/issue posting. 

Architecture Highlights

• Central server hosts the web app and integration services; handhelds connect      over Wi‑Fi. 
• SAP S/4HANA Public Cloud integration for inbound GRN creation data,      reservations, and postings; flexible Gateway/PI/PO/FTP options. 
• Label printer and rugged Android scanners (e.g., Zebra TC22) ensure reliable barcode operations on the shop floor. 

• Traceability:     Package-level QR codes + batch-linked GRNs deliver end‑to‑end visibility from gate to issue. 
• Compliance:     FIFO validation at pick minimizes aging inventory and expedites correct consumption. 
• Efficiency:     Scan-driven workflows reduce manual errors, cut search time, and      accelerate put‑away and picking. 
• SAP Data Integrity: Direct postings and synchronized references (PO, GRN,      Reservation, Picklist) improve reconciliation. 

Mazeworks Solutions delivered a web-and-mobile solution that digitizes gate entry, GRN creation, package-level labeling, put-away, reservation, picking, and SAP postings—providing end-to-end traceability and operational discipline.