Zebra RFID lifts Spex warehouse picking efficiency 50%

Zebra Technologies has deployed RFID systems at Spex to modernise the New Zealand manufacturer's warehousing and fulfilment operation, lifting picking efficiency by more than 50%.

Spex, which makes wheelchair accessories, rehabilitation tools and other mobility products as part of Medifab Global Group, had managed picking and dispatch with manual barcode scanning, checklists and paper order sheets for more than 30 years. As its product range, order volumes and international footprint grew, that process became harder to manage.

Delivered with implementation partner Synergic Technologies, the new set-up combines Zebra's MC3300 RFID mobile computers for warehouse picking, ZT400 industrial printers for shipping labels and FX9600 fixed RFID readers for shipment scanning.

Zebra's MotionWorks software links the hardware and collects operational data across the process, creating real-time inventory visibility and automating verification at dispatch.

Before the change, Spex faced a recurring problem when customers reported missing items. Paper-based records did not provide clear proof of what had been sent, leaving the company exposed to replacement costs and delays in resolving disputes.

With the RFID process in place, workers use handheld devices to locate items for picking, then print shipping tags before orders move through a checking station. There, a fixed reader completes an automated check in 10 seconds and updates the company's ERP system.

According to the companies, the system has reduced picking time for some tasks from 15 minutes to five minutes. Spex also said the verification step has helped it achieve near-perfect dispatch accuracy.

Operational changes

The shift gives Spex a digital record of product movements through the warehouse, including serial and lot histories. Beyond day-to-day dispatch, that allows the manufacturer to investigate quality issues, handle recalls and answer customer queries with more certainty.

Improved traceability has also reduced unnecessary replacement shipments. In a medical equipment supply chain, where customers may depend on products arriving complete and on time, fewer fulfilment errors can also reduce pressure on support teams.

Shaun McDonald, Integrations Engineer at Spex, described the impact on warehouse workflows in a statement.

"By reducing 15-minute picking tasks to five minutes, Zebra's RFID solutions have cut our picking times by over 50% while helping us achieve near-perfect dispatch accuracy," said Shaun McDonald, Integrations Engineer at Spex.

"This has reinforced the trust our customers place in us to deliver every order correctly, giving us absolute certainty without sacrificing efficiency and speed," McDonald said.

Manufacturing focus

The deployment reflects a broader push by manufacturers and distributors to replace paper-based warehouse processes with automated tracking and verification. RFID has been used for years in logistics and retail, but manufacturers with complex product catalogues and growing export operations are also adopting it to tighten inventory control and reduce manual checking.

For Spex, the use case centres on products that require accurate fulfilment and clear shipment records. The company's output includes mobility-related equipment for customers whose needs may be urgent and specific, making dispatch errors harder to absorb than in less specialised consumer markets.

Zebra said the project shows how real-time item visibility can reshape frontline warehouse work by reducing search time and replacing manual confirmation steps. The company has been expanding its position in asset tracking, labelling and mobile computing across sectors including healthcare, logistics and manufacturing.

Brian Van Ginkel, Country Manager for New Zealand at Zebra Technologies, said the Spex project highlighted the operational pressures facing manufacturers.

"Equipping a connected frontline with RFID technology is essential for modern manufacturers facing growing delivery pressures," said Brian Van Ginkel, Country Manager for New Zealand at Zebra Technologies.

"Spex's success is a powerful example of how real-time inventory visibility empowers workers to modernise operations and deliver reliable service to the customers who depend on their mobility solutions the most," Van Ginkel said.