Case Study - Labour Productivity
60% Reduction in Manual Labour Through Warehouse Automation
Manual warehouse processes consume people and create errors. By automating receiving, binning, consumption tracking and returns, Ajinkya Technologies helped an operation reduce manual labour by 60% while improving accuracy.
It is a focused example of one of the highest-return moves in any warehouse or plant: identify the high-frequency, repetitive manual tasks and automate them end to end, so the team does more with the same headcount and far fewer mistakes.
Free scoping call. We start with one line, never change your machine logic, and you own the code and the data.
The challenge
The warehouse depended on people to receive goods, bin them, track consumption and process returns - all manually recorded. This was labour-intensive, error-prone and hard to scale, with significant staff time spent on repetitive data entry and physical searching rather than value-adding work.
The operation needed to do more with the same team, cut the error rate, and free people from the most repetitive tasks - without disrupting day-to-day flow.
The solution Ajinkya Technologies built
We automated the full cycle: receiving, binning, consumption tracking and returns. RFID and barcode capture replaced manual logging, the system directed put-away and picking, and consumption and returns were recorded automatically as they happened.
With automated capture and real-time inventory, staff no longer chased paperwork or searched for stock - the system told them where things were and recorded movements without manual keying.
Crucially, the automation was layered onto the existing operation in phases, so the warehouse kept running throughout and the team adapted to each change incrementally rather than facing a single disruptive switchover.
- Automated receiving and directed binning
- Automatic consumption tracking and returns processing
- RFID and barcode capture replacing manual logging
- Real-time inventory eliminating manual searches and reconciliation
The measurable result
Automating receiving, binning, consumption tracking and returns reduced manual labour by 60%. The same team now handles substantially more volume, error rates dropped, and people were redeployed from repetitive data entry to higher-value work.
The result is a leaner, more accurate operation - proof that targeted automation of the right manual processes delivers immediate, measurable productivity gains.
Why labour automation pays back quickly
Labour spent on receiving, binning, consumption tracking and returns is pure overhead - necessary, but adding no differentiation. Automating it does two things at once: it cuts cost by reducing the manual effort by 60%, and it raises quality by removing the human error inherent in repetitive data entry.
Because these processes are high-frequency and well-defined, they are ideal automation candidates with fast payback. The freed capacity is then redeployed to work that genuinely needs human judgement - the most durable form of productivity gain in a warehouse or plant.
Explore related solutions
Common concerns, answered
Will this disrupt production?
No. We connect read only first, install during planned stops, and edge devices buffer data so a network problem never stops a machine. Nothing writes to a PLC without your controls team and a test.
Our machines are old. Do we need to replace them?
No. Old machines are the usual case. A running signal, a cycle signal or a current sensor on the motor is enough to start, without touching the machine program.
We tried a system before and nobody used it.
That is the most common failure, so we design with the operators and supervisors who will use it, start with one report they already fill in by hand, and only extend once they rely on it.
What about IT security?
Read only by default, a segmented OT network, and a review with your IT team before anything connects, following the ISA/IEC 62443 zone approach.
We will not replace SAP or Oracle. Do we have to?
No. We connect to the ERP you already run through its standard interfaces and add what the shop floor is missing. Your ERP stays the system of record.
Do your engineers understand a heavy industrial floor?
Our systems run in steel plants, warehouses and process lines. We start every project by walking the line with your operators and supervisors, and the first release is tested by them, not only by IT.
Are we locked in?
No. You own the source code and the data, documented, in your own repository. Another team can maintain it.
Free your team from manual work
Tell us which manual processes are draining your team and we will scope automation with measurable labour savings.
Step 1
An engineer reads it
Not a sales bot. Our team replies within 24 hours with questions or times for a call.
Step 2
30 minute call
Your process, machines, systems and the number you want to move. We tell you honestly if we are a fit.
Step 3
A written scope for one line
What we would connect, what you would see, how long it takes. You decide; nothing starts without your approval.