Success Story

Developing an IoT-based Asset Tracking solution for Johnson Controls International

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Johnson Controls International is an American Irish-domiciled multinational conglomerate headquartered in Cork, Ireland, that produces fire, HVAC, and security equipment for buildings. As of mid-2019, it employed 105,000 people in around 2,000 locations across six continents. The company is listed on the NYSE as JSI.

It has the world’s largest portfolio of building technology, software, and service solutions and has been delivering its services to prime industries such as healthcare, schools, data centers, airports, stadiums, manufacturing, etc.

  • 2000+ worldwide locations
  • 100,000+ employees
  • $22 B worldwide sales

Business Situation

Johnson Controls International (JCI) offers the largest portfolio of HVAC equipment and controls in the world. They recognise technology as its key differentiators and growth enablers. However, legacy ERP systems and semi-manual workflows were among the key hurdles for further expansion and increasing profit margins.

Team Daffodil conducted a few pre-sales sessions with JCI to understand the challenges encountered by their warehouse management team. Amongst the various issues that were highlighted by JCI, warehouse theft and manual data entry into the ERP were some of the most problematic issues. While the theft was causing substantial loss to the business, manual entry to the ERP was paving the way for it. 

Thus, JCI was on the lookout for a technology partner who could demonstrate market-knowledge in the logistics industry and help them overcome the challenges through a multi-faceted warehouse asset management solution. JCI chose Daffodil Software for our best cost/value balance, extensive expertise in the logistics industry, state-of-the-art processes, and innovation-led culture. The key requirements were to:

  • Provide full-cycle product development and includes business analysis, product design, software architecture, data science, software development, quality assurance and implementation of an asset management system that could provide a bird’s eye view of the movement of assets across the warehouse and maintain a comprehensive record of the entire inventory.
  • Develop a scalable and robust architecture for the application which could help them scale and deploy the application in other warehouses across the globe.
  • Provide a real-time dashboard for the management to view all the information in a graphical manner for quicker and real-time assistance in decision making.

The Solution

After understanding the pain points and requirements of the JCI warehouse management team, an IoT- based solution was proposed by team Daffodil. The entire idea was executed following Daffodil’s Discover & Frame (D&F) workshop.

D&F is Daffodil’s proprietary approach to materialize a product idea. It helps to have an in-depth understanding of an idea, targeted users, competitors, use cases, limitations & technical risks, etc. 

Following the D&F approach, an RFID asset tracking solution was developed to automatically scan all the tagged assets inside a warehouse and update their information on a mobile app. The RFIDs are attached to the inventory and are scanned along with the serial number. Once the items are scanned with this information, it gets saved into the asset tracking solution with PO reference. The Goods Received Note (GRN) and Serial Number (SN) file is generated, kept for record in the system, and sent to the ERP system. 

Along with the mobile app, a web application was developed that gives a bird’ eye view of inventory, generates reports, and exports them. The dashboard gives an overview of factors such as the number of inventory, check-in & check-out count inventory status (disposed of, lost, available assets), inventory asset category, etc. The admin can manage inventory (add, remove, or checkout management). Also, users and their permissions can be managed through the web app. The reports are generated and graphically presented in the web portal (check-in report, backend job report, check-out report, warehouse information, etc.)

To keep the solution secure, the application does not communicate with any third-party solution. Every service within the app has been customized by team Daffodil to ensure that data and warehouse services are securely retained. 

The Impact

JCI team was extremely satisfied by the way Daffodil has executed the entire project. The client was able to launch the solution in a timely and desired manner as Daffodil ensured that the deliverables were provided on time while maintaining the utmost quality. The warehouse management team of JCI is utilizing mobile and web solutions for asset management and has experienced a 60% faster delivery timeline. Moreover, there are zero cases of asset theft in the warehouse from the time the asset tracking solution is installed for warehouse management.

  • 2000+ worldwide locations
  • 100,000+ employees
  • $22 B worldwide sales

 

“As Johnson Controls expands its focus from manufacturing HVAC, fire detection, and building controls products to providing predictive analytics and smart facilities, Johnson’s end-to-end processes must be “digital to the core.”

Diane Schwarz,

 CIO, JCI

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