Streamlining Trailer Operations:
Saving 2340 Work Hours and 50% Data Input Time for Carrier

About the client

Carrier is a global leader in heating, ventilation, and air conditioning (HVAC) solutions. With 1,300 facilities and operations in over 160 countries, they focus on intelligent climate and energy solutions, including air conditioning, refrigeration, and building controls. Carrier is also committed to reducing energy consumption and creating sustainable solutions for a greener planet.

Challenges

The warehouse operations at the Carrier’s US plant location (Collierville, Tennessee) were facing significant challenges primarily due to the use of legacy systems.

Time-consuming manual data entry led to typos and delays in receiving Advance Shipment Notices (ASNs).
Legacy applications were hindering development and deployment by providing a poor user interface, resulting in inefficiencies in the trailer opening and closing process.

These challenges were impacting warehouse staff, dock door leads, and freight carriers, causing delays and affecting on-time delivery to customers.

LTIMindtree Solution

LTIMindtree’s approach to this project involved a collaborative and iterative methodology of implementing automated warehouse systems. Given that futuristic automated warehouse systems are being rapidly adopted in the manufacturing industry, Carrier partnered with LTIMindtree to implement a comprehensive solution, which enabled real-time data capture, automated warehouse systems, and improved visibility into trailer operations, resulting in significant efficiency gains, cost savings, and improved customer satisfaction.

Assessment and analysis

Assessment and analysis We conducted a thorough assessment of the existing trailer operations and legacy applications, identifying pain points, inefficiencies, and opportunities for improvement.

Solution design

Solution design We designed a comprehensive solution, leveraging our expertise in automation in logistics management and process improvement. We also re-platformed the legacy application to a low-code Power Apps platform, enabling faster development, deployment, and improved user experience.

Functionality upgradation

Functionality upgradation We upgraded the Total Operations Processing System (TOPS) program to enhance its functionality and integration.

Seamless data exchange

Seamless data exchange We enhanced and improved the Freight Governance (FGOV) code to ensure seamless data exchange and validation.

Testing and quality assurance

Testing and quality assurance We conducted thorough testing and quality assurance to ensure the solution was free of defects.

Implementation

Implementation We implemented new Keyence handheld devices to automate the trailer opening and closing process, reducing manual data entry and increasing accuracy.

Deployment, training, and collaboration

Deployment, training, and collaboration After deploying the solution, we provided training to warehouse staff, dock door leads, and freight carriers for a smooth transition. We also ensured enhanced collaboration and communication to improve trailer loading and unloading processes.

Monitoring and evaluation

Monitoring and evaluation We monitored the solution’s performance and evaluated its impact on trailer operations, making adjustments and improvements as needed.

Further improvements

Further improvements We analyzed data to identify trends and areas for further improvement and on-time delivery.

Reduced waste

Reduced waste We identified opportunities to reduce waste and optimize resources, such as eliminating unnecessary printing of shipping documents.

Scaling

ScalingWe considered scaling the solution to other locations or departments to achieve similar efficiency gains and cost savings.

Business Benefits

Savings of 2340 work hours

in terms of total savings per annum in warehouse waiting time to receive ASNs faster.

Savings of 300 work hours

per annum in time taken for data input per trailer

Savings of 600 work hours

per annum in automated printing of bills and packaging slips

50% reduction in data input time

per trailer

4% increase in on-time delivery

for customers

Client testimonial

Thank you for finally upgrading our TOPS program after all these years. We are better off with this technology and should be able to capture the mistakes and prevent issues created by shippers. These types of continuous improvements are welcome and much appreciated. I cannot go without appreciating your assistance in rewriting the FGOV code, which has been a huge issue for years and will assist us in managing the process going forward.

Karthik Visvanathan

Associate Director, Engineering, Carrier

Transforming Warehousing Operations with Innovation

We empower businesses to overcome operational challenges with cutting-edge solutions that drive efficiency, reduce costs, and enhance user experiences. Our collaboration with Carrier showcases the transformative power of technology in revolutionizing warehouse operations.

Through automated warehouse systems and legacy application re-platforming, we enabled Carrier to achieve remarkable efficiency gains, eliminate manual data entry errors, and improve overall operational performance. The solution also delivered significant annual time savings, enhanced data accuracy, and boosted on-time delivery rates, setting new benchmarks for operational excellence.

With our transformative automotive solutions, businesses can unlock the potential of innovation to optimize their operations, scale seamlessly, and stay ahead in an ever-evolving marketplace.

Transforming Warehousing Operations with Innovation

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Streamlining Trailer Operations: Saving 2340 Work Hours and 50% Data Input Time for Carrier