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.
The warehouse operations at the Carrier’s US plant location (Collierville, Tennessee) were facing significant challenges primarily due to the use of legacy systems.
These challenges were impacting warehouse staff, dock door leads, and freight carriers, causing delays and affecting on-time delivery to customers.
LTM’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 LTM 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
We conducted a thorough assessment of the existing trailer operations and legacy applications, identifying pain points, inefficiencies, and opportunities for improvement.
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
We upgraded the Total Operations Processing System (TOPS) program to enhance its functionality and integration.
Seamless data exchange
We enhanced and improved the Freight Governance (FGOV) code to ensure seamless data exchange and validation.
Testing and quality assurance
We conducted thorough testing and quality assurance to ensure the solution was free of defects.
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
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
We monitored the solution’s performance and evaluated its impact on trailer operations, making adjustments and improvements as needed.
Further improvements
We analyzed data to identify trends and areas for further improvement and on-time delivery.
Reduced waste
We identified opportunities to reduce waste and optimize resources, such as eliminating unnecessary printing of shipping documents.
Scaling
We considered scaling the solution to other locations or departments to achieve similar efficiency gains and cost savings.
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
" 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
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.
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