Business Challenge

Premium Guard's supply chain is complex, with a high expectation of accuracy from auto parts retailers, distributors and aftermarket businesses. Ensuring the right part and the right quantity shipped to the correct destination on time are critical, as delays or errors can result in customer dissatisfaction and costly chargebacks.

“We ship high volumes weekly to multiple automotive aftermarket retailers, often filling entire truckloads with each order. Manually double-checking and auditing every pallet is overwhelming, yet missing products can lead to costly chargeback fees. After discovering the capabilities of RFID technology, we partnered with Levata to implement a smarter solution—enhancing visibility, improving accuracy, and elevating customer service,” said Jim Allosso, Director of Warehouse Operations at Premium Guard.

Key challenges included:

• Mis-shipments leading to chargebacks and return freight payments

• Inventory discrepancies impacting operational efficiency

• Lack of real-time visibility in warehouse operations

Recognizing the need for improvement, PGI’s leadership committed to a solution that would ensure customers received exactly what they ordered, leading to the adoption of an RFID-based workflow.

The Solution

Premium Guard needed a partner that could provide customized, cutting-edge technology that addressed key challenges in supply chain management. Levata's RFID systems, such as RFID tunnels, dock doors, and mobile readers, offer accurate inventory tracking and real-time visibility, which are critical for reducing mis-shipments, lowering chargeback costs, and improving operational efficiency.

With Levata, PGI has launched a phased RFID implementation. PGI sought to enhance customer service through enhanced inventory management operations for its largest customer, a leading national retailer of automotive parts and accessories. The solution involved multiple components tailored to PGI’s unique operational needs. PGI committed to an extensive relabeling project to fully integrate RFID technology effectively, involving the relabeling of over 600,000 boxes. Additionally, ten vendors began incorporating RFID labels into their shipments, further streamlining PGI’s receiving process.

RFID Infrastructure & Technology – A custom-built RFID Tunnel (SLS T-Series) was integrated with PGI’s ERP system to count pallet content accurately and validating that shipments include the right materials. RFID Dock Doors (SLS D-Series) were installed to ensure shipments were loaded onto the correct trucks, while RFID Mobile Readers (SLS M-Series) supported cycle counting of pallets in the warehouse. To provide real-time tracking and data insights, PGI leveraged the SLS View RFID cloud software.

To further streamline operations, PGI deployed powered mobile carts equipped with RFID label printers and AirTrack Performance label supplies, allowing for efficient RFID labeling right on the warehouse floor. Additionally, handheld mobile RFID readers and mobile computers enabled mobile scanning and verification, creating seamless interaction with the RFID system powered by cloud-based software.

“From day one, we’ve worked with a dedicated Levata team deeply involved in every phase of our project,” said Jim. “Their solution architects designed a highly customized system, field experts collaborated directly with our floor teams, and specialists guided our manufacturing partners through new processes. No matter the challenge, Levata has been there with reliable support we can count on.”

Benefits and Results

Premium Guard has already seen significant improvements with the new system:

• Highly accurate scanning, with both the RFID tunnel and dock doors performing exceptionally well

• Enhanced insights from customized reporting

• Stronger supply chain visibility, reducing inefficiencies and ensuring greater accuracy in shipments

With the success of the initial phase, PGI is planning to expand their RFID implementation. It will roll out the new process for other large customers, resulting in a dedicated dock door for each customer for smooth, efficient order verification. The expansion will include more vendor participation, too. Having vendors ship parts with RFID labels enables seamless integration with the warehouse's RFID system, improving inventory accuracy, accelerating processing times, and enhancing overall supply chain efficiency.

By leveraging Levata’s advanced RFID solutions, PGI has significantly improved its supply chain efficiency, reduced operational costs, and strengthened its reputation as a reliable partner in the automotive aftermarket industry.