For manufacturers in Thailand, production lines are becoming more automated, but warehouse operations often remain dependent on manual input, visual checks, and individual experience. Receiving materials, storing them in the correct location, issuing labels, and confirming inventory may look like routine work. In reality, these processes determine whether production can run with accurate data and stable supply.
Minebea AccessSolutions Thai (MAST), an automotive parts manufacturer in Thailand, faced the same operational challenge. The company needed to improve the accuracy and speed of its procurement warehouse without discarding its existing AS400 core system. TOMAS TECH supported MAST by building a QR and barcode scanning system connected to AS400, together with a unified label operation for warehouse processes.
The result was not just a system installation. After go-live, MAST achieved zero inventory discrepancy, a major reduction in manual input, faster inspection work, and a reduction equivalent to two warehouse staff members. These outcomes show how a focused warehouse improvement project can create measurable value for a manufacturing site.
The Challenge
Before the project, the procurement warehouse depended heavily on manual work. Operators had to input material information, confirm quantities, check storage locations, and correct differences when actual inventory did not match system records. In a manufacturing environment, inventory discrepancy is not a small administrative issue. It can affect purchasing, production planning, line operation, quality control, and delivery.
Another important point was the existing AS400 environment. MAST did not need a complete system replacement. The real requirement was to keep the existing backbone system while making the shop-floor operation faster and more accurate. This is a common situation for Japanese manufacturers in Thailand. Many companies already have established systems, but the physical warehouse process is still not sufficiently digitized.
The Solution
TOMAS TECH designed a QR and barcode scanning operation that connects the warehouse floor with AS400. Operators can scan labels and register material receiving, storage, and inventory movement more accurately. By reducing manual input, the system also reduces the source of errors.
The project also introduced a unified label concept. Labels are not merely printed documents. In warehouse operations, labels are the bridge between physical goods and digital records. When the label format is consistent, operators know what to scan, when to scan, and how the data will be registered. This standardization is one of the key reasons the system could improve accuracy in daily operations.
Implementation Approach
The project started with the procurement warehouse. This phased approach made the implementation practical. Instead of changing the whole factory at once, TOMAS TECH focused on an area where the problem was clear and the result could be measured. The operation was designed around real warehouse movements, scanning timing, label issuance, and exception handling.
For a successful warehouse system, usability matters as much as system logic. If operators cannot use the system naturally in daily work, the expected benefits will not appear. TOMAS TECH combined knowledge of manufacturing operations, warehouse processes, label control, and system integration to create an operation that could be used on site.
Results
- Zero inventory discrepancy after go-live
- Major reduction in manual input through scanning
- Faster receiving inspection
- Labor saving equivalent to two warehouse staff members
After implementation, MAST achieved zero shelf discrepancy in the target warehouse operation. Manual input was significantly reduced because scanning replaced repeated typing and checking. Inspection speed improved because operators could confirm required information through the scanner and label flow. The project also created a labor-saving effect equivalent to two warehouse staff members.
These results are especially meaningful for manufacturers in Thailand. Labor availability, cost pressure, quality requirements, and traceability needs are all increasing. A warehouse system must therefore do more than record inventory. It must help the site operate with fewer errors, less rework, and better visibility.
Why This Case Matters
This case shows that digital transformation in manufacturing does not always have to begin with a large ERP replacement. A company can start from the warehouse, connect the existing core system, standardize labels, and digitize daily scanning operations. When this is done correctly, the impact is visible: better inventory accuracy, faster work, and reduced dependency on manual input.
For Japanese manufacturers in Thailand, this approach is highly practical. Existing systems such as AS400 can remain in place while the warehouse operation becomes more digital. The next opportunity is to expand from procurement warehouse management to work-in-process inventory and production execution. Once material movement becomes accurate, the entire factory can move toward better data-driven management.
TOMAS TECH’s Value
TOMAS TECH provides more than software development. The value lies in designing a system that fits real manufacturing operations in Thailand. With experience in WMS, MES, production management, label issuing, and inventory movement, TOMAS TECH can connect business rules, existing systems, and shop-floor behavior.
The MAST project demonstrates this strength. By linking AS400 with QR scanning and a unified label operation, TOMAS TECH helped turn a manual warehouse process into a more accurate and scalable operation. For manufacturers that want to improve inventory accuracy, reduce manual work, or connect existing systems with warehouse operations, this case provides a concrete example of what can be achieved.
