Badger's key technology is the Badger Hydrovac™, which is specialized mobile machinery used primarily for safe excavation around critical infrastructure and in congested underground conditions. The Badger Hydrovac uses a pressurized water stream to liquify the soil cover, which is then removed with a powerful vacuum system and deposited into a storage tank. Badger is unique in the non-destructive excavation industry because it designs and manufactures all of its hydrovac units at its plant in Red Deer, Alberta, which has an annual production capacity of more than 350 hydrovac units. To complement the Badger Hydrovac and extend the Badger's service offerings, the Badger has a select number of specialty units, mainly combo trucks, sewer and flusher units, and airvacs.
In order to address certain inventory management challenges, Badger partnered with RF-SMART for Oracle Cloud to optimize their warehouse operations. With approximately 10,000 SKUs and three product lines, Badger required a barcode scanning solution capable of handling and managing complex inventory across multiple facilities in North America.
Beyond Paper-Based Processes
Before RF-SMART, Badger heavily relied on manual, paper-based workflows. These outdated processes led to inventory inaccuracies and operational bottlenecks. As Badger continues to grow across multiple facilities, they required a solution that could seamlessly connect their physical operations with Oracle Cloud.
The Badger team was looking for a partner who understood their manufacturing environment and could provide both out-of-the-box functionality and customization options. RF-SMART's proven track record with Oracle Cloud integration made them the clear choice for Badger's mobile inventory management needs. The robustness of RF-SMART's inventory solution, combined with its adaptability, provided the perfect balance for Badger's requirements. "We felt that RF-SMART offered the flexibility to configure or tailor the software to our needs - that was really the sweet spot we were looking for," said Janina Hutchinson, Director of Supply Chain.
A Helping Hand
To mitigate the risk of efficiency, productions delays, and inventory inaccuracies due to the time spent on manual processes, Badger implemented RF-SMART’s Manufacturing and Inventory Management module. This comprehensive suite of tools, specifically designed for manufacturing and inventory management within Oracle Cloud, allows Badger’s users the ability to perform mobile transactions such as receiving, picking, and cycle counting. With the adoption of this software, Badger avoids interruptions caused by outdated workflows within the facility.
Transforming Receiving Operations
The implementation of RF-SMART further improved Badger’s receiving processes through mobile scanning capabilities and real-time system updates. "It allows the receivers to be mobile, eliminating the need to constantly walk back and forth between the computers," said Janina. This increased mobility translates to improved efficiency and reduced processing times.
Moreover, RF-SMART provides Badger staff proper bin location control, replacing their previous approach of memorizing inventory locations with a reliable, systematic code. This change makes inventory tracking and retrieval significantly more efficient, as warehouse staff can now easily locate items without relying on personal knowledge or outdated paper records.
Streamlining Picking Operations
Prior to RF-SMART, Badger’s picking process was document-driven, demanding, and not integrated with their shop floor system. This disconnect led to inefficiencies and challenges in aligning the system-driven picking with the actual production line requirements. "Before, we would print off pick lists and spreadsheets, then perform the picking in Oracle afterward, which consistently resulted in a timeline disconnect," said Janina.
By implementing RF-SMART’s Kanban-based picking system, Badger effectively streamlined their picking processes. RF-SMART's Kanban Solution facilitates real-time picking for welding, electrical, assembly, and painting product lines, ensuring items are selected in the correct sequence for production. This updated process enhances their Kanban-based picking system by aligning physical shop floor operations with system data, guaranteeing immediate accuracy and efficiency.
Dynamic Improvements with Cycle Counting
Along with implementing RF-SMART receiving and picking, RF-SMART also plays a crucial role in automating Badger’s counting processes, leading to significant improvements in inventory accuracy and efficiency. Before implementing RF-SMART, Badger relied on traditional counting methods using pen, paper, and Excel spreadsheets, which were time-consuming and prone to errors.
With RF-SMART, Badger implemented an ABC classification system for cycle counting, allowing them to prioritize items based on their value. "In just three months after adopting RF-SMART’s cycle counting solution, our inventory accuracy improved by 20%, which was exceptional," said Janina. Oracle Cloud generates a list of items to be counted each Friday, enabling warehouse staff to efficiently count using RF-SMART’s handheld scanners. Real-time updates to Oracle Cloud provide immediate visibility into discrepancies, automatically triggering recounts when necessary. "It's a great system – it self-validates when the count aligns with Oracle, and automatically initiates a recount if there's any discrepancy," said Rob Byers, Warehouse Manager.
Future Plans
Partnering with RF-SMART has not only significantly improved inventory accuracy and operational efficiency across Badger's facilities, but it also paved the way for future improvements. The partnership between Badger and RF-SMART continues to evolve as new opportunities for improvement are identified. “It is exciting to think that there are more opportunities to elevate our manufacturing operation,” said Rob.