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Challenge
Iron Fortress picked orders manually using printed lists
They needed one person to pick and another to validate afterwards
Inefficient use of employee time, slowing down order fulfillment.
Iron Fortress, headquartered Denmark, has earned global recognition as the leading manufacturer of role-playing equipment. Their products, shipped to major markets like the USA, Canada, and Japan, have even been featured in blockbuster franchises like Star Wars.
As demand for their products grew, so did the complexity of their warehouse operations. Their team faced inefficiencies and errors that their existing system simply couldn’t handle, prompting them to search for a more effective solution.
Iron Fortress picked orders manually using printed lists
They needed one person to pick and another to validate afterwards
Inefficient use of employee time, slowing down order fulfillment.
Replacing paper-based picking with digital and real-time barcode scanning.
Automating their picking, shipment, and invoicing processes
Enabling real-time validation to eliminate picking errors and streamline workflows.
50% faster order picking, exceeding their initial 25% time-saving expectations.
Drastically reduced errors, as validation is now handled by the system instead of requiring an extra employee.
Increased employee satisfaction, as the digital system eliminated repetitive, manual work.
The challenges Iron Fortress faced were rooted in their outdated warehouse management system. They relied on Microsoft Dynamics C5 and a barcode solution where employees pick orders manually using printed lists. This process was slow and frequently disrupted when new stock arrived:
"We had to print paper lists for picking, and every time new items came in, we had to reshuffle the order of them due to a numeral system we had. It was time-consuming and caused a lot of picking errors," recalls Brian Holte, Inventory Inquisitor at Iron Fortress.
The paper-based system also required additional resources. One person picked items, while another validated the work to ensure accuracy. Despite these efforts, picking errors were common and their team’s time was used inefficiently.
One of the first noticeable changes after implementing the solution was in the picking process. With Tasklet, tasks are sent directly to the mobile scanners, eliminating the need for printed lists. The scanners provide guidance, and all the information needed, streamlining the entire process: "The scanner tells us exactly where items are, how many we need, and even the aisle location. It has made our warehouse much more efficient," Brian explains.
Real-time validation ensures that if an employee scans the wrong item, the system immediately alerts them. This eliminates the need for double-checking and drastically reduces errors: "Before Tasklet, we needed one person to pick and another to validate. Now, the scanner does that for us, and errors are close to non-existent," he adds.
Beyond improving their picking process, the solution automated their manual workflows. When a sales order is released, the system automatically generates shipment and picking tasks, sending them directly to the scanner. Once picking is complete, the system invoices and posts to the customer without manual intervention:
"It’s seamless now. The system handles everything, from generating picking tasks to invoicing customers. We no longer have to manually close invoices—it’s all done automatically," Brian shares. This level of automation not only saves time but also empowers the team with the optimal setup to process and fulfill orders seamlessly and efficiently.
The efficiency gains have been substantial. Initially, Iron Fortress anticipated saving 25% of their time with Tasklet, but they quickly realized the system delivered even more: "With Tasklet, we have cut down our order picking time with 50%. The process is much faster now, and employees can focus on what really matters, which is creating value for our customers," says Brian.
The transition from manual to digital was also well-received by employees, who appreciated the system’s simplicity and functionality: "At first, some team members were hesitant, but they soon saw the benefits. They no longer need to deal with paper lists or walk back and forth to the computer to enter data. Everything is on the scanner, and that makes their job much easier," Brian notes.
Tasklet’s ability to adapt to individual needs was another advantage, they experienced. For example, the multi-language support allowed the team to accommodate employees with different preferences when it comes to language, further enhancing its usability.
For Iron Fortress, the new setup wasn’t just about saving time—it was about doing things right. Brian emphasizes that accuracy comes first - and speed improving naturally through repetition: "We teach our employees to focus on doing things correctly. Speed comes with experience, and Tasklet ensures that everything is done right the first time," he explains.
With streamlined operations, reduced errors, and happy employees, Iron Fortress has laid the groundwork for keeping up with their growth: "Tasklet has been a game-changer for us. It’s reliable, easy to use, and has completely changed the way we operate in our warehouse," Brian concludes.
Iron Fortress is a leading manufacturer of high-quality role-playing gear based in Denmark, specializing in safe and functional apparel and equipment for historical re-enactment, live-action role-playing, and entertainment productions. Iron Fortress serves enthusiasts worldwide, with a strong presence in markets like the USA, Canada, and Japan and are trusted by top franchises, including Star Wars.
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