Case Study: Transitioning B2B Electronic Accessories Business To a Unified WMS

Learn How FOYCOM's End-to-End RFID Cloud Solution for a US-based B2B Electronics Accessories Platform helped to Streamline Operations & Get Better Insights into Business.

In the ever-changing world of B2B e-commerce, inventory accuracy and operational efficiency are not just goals but are crucial. A US-based B2B electronic accessories e-commerce business, with three warehouses, was struggling with fragmented warehouse management systems, resulting in inventory inconsistencies, rising software costs, and delayed order fulfillment.

In partnership with FOYCOM, they replaced their old WMS platforms with a FOYCOM RFID-powered system, fully integrated with a cloud analytics dashboard, to simplify operations and drive efficiency. This resulted in the elimination of system fragmentation, reduction in IT overhead, and an impressive 99.98% inventory accuracy, leading to faster, more reliable order fulfillment.

This case study delves into how FOYCOM's RFID-native WMS streamlined warehouse operations, improved decision-making, and helped the client stay ahead in a competitive market. Continue reading to learn more.

Challenges Faced By The Client

The client had disbursed electronics accessories, such as charging cables, adapters, and power banks, in three warehouses. Each one of them had previously utilized a different WMS.

Warehouse A: SAP Extended Warehouse Management (SAP EWM)
Warehouse B: Oracle Warehouse Management Cloud (WMS Cloud)
Warehouse C: Oracle Warehouse Management Cloud (WMS Cloud)

Key Pain Points Of Electronics Accessories Distributor:-

Multi-WMS Complexity

Uncooperative systems made it difficult for cross-warehouse transfers and reconciliation.

High Licensing Costs

It incurred more than $200,000 every year in sustaining the three WMS licenses.

Data Silos

There was no centralized visibility resulting in stockouts and overstocking.

RFID Incompatibility

Legacy WMS didn't natively support RFID, and there was hard-coding with manual data entry involved.

Metal Interference

Traditional RFID tags were unable to track metal-dense products, such as aluminum chargers.

Slow Order Processing

Manual workflows and disconnected systems led to fulfillment delays and shipping errors.

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FOYCOM's Solution: Unified WMS with Embedded RFID and Cloud Analytics Dashboard

FOYCOM replaced the client's multi-WMS infrastructure with its all-in-one WMS, built specifically for RFID-driven inventory management and cloud scalability. The solution was built upon three pillars.

FOYCOM wms

FOYCOM's WMS was built natively for RFID workflows so that no middleware was required to be used from third parties. The key features were:

RFID Integration
Direct API connectivity with RFID readers for real-time data ingestion.

Multi-Warehouse Orchestration:
Centralized stock transfer control, demand forecasting, and replenishment across the three warehouses

Automation Rules
Customizable re-order rules, cycle count rules, exception handling for example, lost or misplaced items.

User Permissions
Role-Based Access Control for the warehouse employees, managers, auditors, and others.

Tags:

Tag type: UHF RFID, that is compliant to EPC Gen2v2

Model : Impinj H47 Metalcraft Metal Skin Tag.

Metal Tolerance: Ferrite-backed adhesive for seamless attachment to metallic surfaces.

Memory: 128-bit EPC + 512-bit user memory (stored SKU, batch, and expiry dates).

Durability: IP69K-rated for resistance to water, dust, and chemical exposure.

Readers:

Fixed Readers: Impinj R720 RFID Readers with Laird S9028PCL antennas.

Frequency: 902–928 MHz (FCC-compliant).

Read Range: Up to 12 meters for bulk pallet scanning.

Integration: Connected directly to FOYCOM WMS via MQTT protocol.

Mobile Scanners: Zebra MC3330xR Handheld RFID Readers for portable audits

Tagging Process:

Products were tagged at the inbound receiving process using print-and-apply machines that encoded RFID tags with product data.
Pallets and storage bins could receive dual-frequency tags for back compatibility in case there was a transition issue.

Data Infrastructure:

Ingestion: AWS IoT Core processed 50,000+ RFID events/minute from fixed and handheld readers.
Storage: Time-series data in Amazon Timestream; transactional records in Aurora PostgreSQL.
Processing: Apache Flink for real-time anomaly detection (e.g., unauthorized stock movements)

Dashboard & Analytics:

Unified Inventory View: Real-time stock levels, location tracking, and cross-warehouse transfer status.
Predictive Insights: ML models analyzed historical RFID data to forecast demand spikes (e.g., holiday seasons).
Compliance Reporting: Automated generation of audit trails for regulatory requirements.
Technical Workflow: RFID to WMS to Cloud
Tag Encoding: Upon receipt, RFID tags were encoded with EPCs linked to product details in FOYCOM WMS.

Automated Inventory Updates:

Dock door fixed readers scanned tags at receiving/staging, auto-updating stock levels in FOYCOM WMS.
Mobile scanners validated picks during order fulfillment, reducing mispicks by 98%.

Centralized WMS Operations:

Stock transfers between warehouses were initiated in FOYCOM WMS, and RFID scans updated inventory in real time.
Replenishment alerts triggered purchase orders when stock fell below minimum thresholds.

Cloud Analytics:

RFID data synced to the cloud for dashboards, predictive analytics, and automated audit reports.

Migration Strategy: Migrate from Legacy WMS

Phase 1 (Warehouse A)

Data migration from SAP EWM to FOYCOM WMS using CSV exports and custom ETL scripts. RFID hardware was installed over a weekend, with parallel testing for 72 hours.

Phase 2 (Warehouse B & C)

Oracle data is consolidated into FOYCOM WMS via JDBC connectors. Staff training sessions are conducted through FOYCOM's e-learning tutorial.

Go-Live

8 weeks for a full transition, with a 24/7 support team resolving over 120 tickets post-launch.

Outcomes & ROI After Moving to FOYCOM

Inventory Accuracy:

99.98% accuracy post-migration, up from 85%.

Cost Savings:

$210,000/year saved on legacy WMS licensing and middleware software and Hardware.
60% reduction in IT staff hours for system maintenance.

Operational Efficiency:

Order fulfillment accelerated by 40% due to unified workflows.
Cycle counts completed in 1 hour per warehouse (down from 40 hours).

Scalability :

Supported a 50% increase in SKUs without additional hires.

Sustainability:

30% reduction in excess stock through AI-driven demand forecasting.

Achieve 99.98% Inventory Accuracy With FOYCOM!

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Conclusion

By replacing fragmented legacy systems with FOYCOM’s unified WMS and RFID-cloud ecosystem, the client eliminated data silos, slashed operational costs, and achieved near-perfect inventory accuracy. The RFID-native architecture and metal-tolerant tags ensured seamless tracking of electronics accessories, while the cloud platform enabled data-driven decision-making. For B2B e-commerce businesses burdened by multi-WMS complexity, this case study demonstrates the transformative power of consolidating inventory management under a single, agile platform.