Walvoil Smart Inward Outward

Eliminating Traceability Gaps in Precision Manufacturing: Walvoil’s SAP Barcoding Journey

Walvoil Smart Inward Outward

Client Profile: Walvoil

Walvoil is a global leader in the design and manufacturing of hydraulic valves, manifolds, and integrated hydraulic systems, serving industries such as construction equipment, agriculture, material handling, and industrial machinery. Known for high-precision engineering and customization, Walvoil operates in a high-mix, low-to-medium volume manufacturing environment.

To maintain strict quality standards and ensure component-level traceability, Walvoil partnered with BSC Global to implement a Smart Inward–Outward Barcoding Solution fully integrated within SAP.

Key Challenges Before Implementation

Walvoil’s challenges were unique to precision manufacturing and customized production:

1. High Variety of Components & Revisions

  • Thousands of SKUs with frequent engineering revisions
  • Difficulty in tracking correct component versions during inward and issue

2. Batch & Serial-Level Traceability Requirements

  • Manual batch tracking led to errors in quality and compliance
  • Limited visibility from vendor receipt to production issue

3. Mismatch Between Physical Stores & SAP

  • Delays in posting inward and outward movements
  • Stock inaccuracies affecting production planning

4. Quality Hold & Rejection Handling

  • Inadequate segregation of:
    • Accepted
    • Rejected
    • Quality inspection stock
  • Risk of wrong material issuance to production

5. Audit & Customer Traceability Demands

  • Difficulty providing quick traceability during customer or quality audits
  • Manual data collation consuming time and effort

Solution Implemented by BSC Global

BSC Global delivered a Smart Inward–Outward Barcoding Solution inside SAP, designed for component-level accuracy and traceability.

Solution Highlights

1. SAP-Native Barcoding for Component Receipt

  • Barcode generation at GR level capturing:
    • Material
    • Batch / serial number
    • Revision level
  • Direct integration with SAP MM & QM

2. Quality Inspection Integration

  • Barcode-based movement between:
    • Quality inspection
    • Blocked stock
    • Unrestricted stock
  • Prevention of incorrect material release

3. Production Issue Control

  • Barcode validation during material issue to shop floor
  • Ensured correct component, batch, and revision issued

4. Outward Dispatch Accuracy

  • Barcode scanning during customer dispatch
  • Automatic SAP goods issue posting
  • Elimination of wrong shipment risk

5. Traceability & Reporting

  • End-to-end traceability from vendor to customer
  • SAP reports for:
    • Batch genealogy
    • Component movement history
    • Quality status tracking

Implementation Approach

  • Detailed analysis of engineering change & material flow
  • SAP enhancements aligned with MM, PP, and QM
  • Barcode hardware deployment at stores and production points
  • User training for stores, QA, and production teams
  • Controlled go-live with phased adoption

Business Impact & Results

  • 100% Component-Level Traceability achieved
  • Reduction in Production Errors & Rework
  • Improved Inventory Accuracy
  • Faster Audit & Customer Traceability Response
  • Better Quality Compliance & Control
  • Higher Confidence in SAP Data for Planning

Why Walvoil Chose BSC Global

  • Strong expertise in SAP for precision manufacturing
  • Proven capability in batch & serial traceability
  • SAP-native barcoding without third-party dependency
  • Focus on quality, compliance, and process accuracy

Conclusion

With BSC Global’s Smart Inward–Outward Barcoding Solution inside SAP, Walvoil transformed its material movement processes into a precise, traceable, and audit-ready system. The solution enabled Walvoil to maintain engineering accuracy, improve quality compliance, and support its high-mix manufacturing operations with confidence and control.