The Pain of Manual Processes
Three years ago, Estyle’s warehouse operations were struggling with manual processes, disorganized workflows, and inventory inaccuracies. “Before RF-SMART, our warehouse was a total mess. Our inventory was inaccurate, our people didn’t know where to go, what to do, or how to do it,” said Pete. Estyle relied on basic IT functions and labor extensive processes, with warehouse teams frequently interfering with each other’s work. “We had shippers running into pickers, just a complete mess,” said Kevin Hansen, Inventory Control Manager.
The lack of a proper tracking system significantly impacted their ability to maintain accurate inventory counts and provide the level of service their customers expected. Estyle needed a supply chain management solution that ensured real-time visibility, tracking, and traceability from receiving to shipping and allowed all parts of their warehouse to flow efficiently.
The Missing Puzzle Piece
“When adding RF-SMART to our NetSuite Bundle, it added a user-friendly piece that we were trying to create here at Estyle,” said Kevin. The initial success in shipping led to a phased implementation across all warehouse operations, including receiving, production, and picking.
RF-SMART’s Menu Item Version provides warehouse staff with clear, task-specific guidance through their mobile devices. Each function displays straightforward instructions tailored to the specific operation being performed. “The RF-SMART device specifically says, ‘Receive PO’, how can you really mess that up right,” said Kevin.
The platform’s accessibility has proven particularly beneficial for Estyle’s multilingual workforce, removing communication barriers and accelerating onboarding processes. “It is very easy to be able to explain RF-SMART to that new employee, even if English isn’t their first language,” said Maricarmen Rivera, Forklift Operator. New employees typically master the system within their first week. “This feature makes it more efficient for us because there are less opportunities for mistakes,” said Kevin.
Life with License Plating
After three years of successfully using RF-SMART, Estyle took another significant step forward with their operations by implementing RF-SMART’s License Plating (LP) solution.
The implementation of License Plating transformed product tracking throughout the warehouse. When products arrive, warehouse workers create a unique identifier for groups of multiple items or quantities called a license plate (LP). These items move to component staging, where production pickers select materials for manufacturing. Once finished products are created, new LPs are generated and stored in the finished goods aisles, where the shipping team can efficiently fulfill sales orders. “We had nothing like that before RF-SMART,” said Kevin. “Before we had the LPs, if a pallet moved from one location to another, we would lose the history once it got to the new location.”
This system provides complete traceability from receiving to shipping, integrated directly into NetSuite, allowing Estyle to track every pallet’s movement and history. “From the receiving side to all the way out the door, we are able to track where that pallet has gone, what bin it’s been to, and who has moved it,” said Kevin.
The results have been remarkable. Within six months, Estyle created approximately 5,000 pallets using License Plating. More impressively, they reduced their picking teams from 14 to 6 while cutting labor costs in half. Inventory accuracy improved dramatically, climbing from the 70s into the high 90s.
RF-SMART’s License Plating solutions provided Estyle with comprehensive inventory traceability capabilities, streamlining their compliance documentation processes. The integrated system delivers complete visibility across their supply chain operations. “We need to be able to show where every item went, how much we received, how much we shipped, and what our available inventory is,” said Pete. With lot and pallet history seamlessly integrated into NetSuite, Estyle now accesses critical inventory information in seconds. “Without RF-SMART, it would be very difficult for us to do that in a quick and timely fashion,” said Pete.
What's Next for Estyle
Looking ahead, Estyle is implementing RF-SMART’s Image Capture functionality to further enhance their traceability and customer service. This feature will allow pickers to photograph pallets and complete orders, providing visual evidence for order accuracy and helping prevent disputes about shipment quantities. “With RF-SMART’s help, we really want to break that 99% inventory accuracy. We want to be world-class; we want to be the benchmark,” said Pete.
The Perfect Partnership
The partnership between Estyle and RF-SMART exemplifies how the right technology solution, combined with strategic implementation and ongoing collaboration, can dramatically transform warehouse operations. From basic manual processes to a highly efficient operation with nearperfect inventory accuracy, Estyle’s journey demonstrates the power of choosing the right warehouse management solution.
As their business continues to grow and evolve, RF-SMART remains a crucial partner in their success, helping ensure that Estyle can maintain its position as the world’s leading hair gel manufacturer while delivering exceptional customer service. “RF-SMART is a huge part of transforming our warehouse
from the unorganized mess that it was, to the highly efficient warehouse it is today,” said Pete.