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ProjectX: GrayMatter Secures a Super-Sized Wi-Fi Solution for Discrete Manufacturer
Problem
A major discrete manufacturer encountered some major operational challenges when it wanted to create a more reliable Wi-Fi network inside a 1-million-square-foot warehouse facility.
For perspective, a 1 million square feet could accommodate roughly 17 American football fields.
Unfortunately for Wi-Fi networks, warehouses aren’t like big, open football fields. Instead, they’re filled with metal shelving, permanent and temporary walls, forklifts, competing RF signals and much more.
The manufacturer’s warehouse is divided into multiple zones with distinct requirements, which poses significant difficulties in ensuring efficient real-time data tracking for inventory management.
The existing Wi-Fi infrastructure was inadequate due to:
- Limited range of Wi-Fi access points, causing connectivity issues, especially as devices roamed across the large space
- Dozens of forklifts and handheld scanners constantly moving throughout the facility, which required seamless data connectivity to track, stack, and deliver products efficiently.
- Various sources of signal interference that compromised the performance and reliability of the Wi-Fi network.
Solution
GrayMatter addressed these challenges by implementing a comprehensive, predictive modeling approach tailored to the manufacturer’s unique warehouse layout and operational needs.
GrayMatter conducted a Wi-Fi audit and deployed nearly 100 Wi-Fi Access Points, strategically placed based on the predictive model to ensure complete coverage across the facility. The model considered variables such as simulated interference, antennae orientation and channel selection to optimize network performance.
Working with the client, GrayMatter meticulously planned the Wi-Fi infrastructure design to cater to the facility's dynamic environment, factoring in the movement of forklifts, handheld scanners, and other mobile devices.
RESULTS
The customized Wi-Fi solution transformed the manufacturer's warehouse operations, resulting in:
Enhanced connectivity and data accuracy, enabling real-time tracking, stacking, storing, and delivery of products without delays or errors
Seamless roaming capability for forklifts and handheld scanners, significantly improving operational efficiency and employee productivity
Reduced instances of signal interference, ensuring consistent and reliable Wi-Fi coverage across the entire facility, irrespective of the specific zone requirements
The manufacturer experienced a notable increase in operational efficiency, reduced downtime, and an overall improvement in the speed and reliability of warehouse operations, setting a new standard in their logistical capabilities