Individual Report
TECHNICAL FEASIBILITY STUDY
FOR INVENTORY CONTROL SYSTEM AT TUNNUP MOTORCYCLES
An Assignment for System Spec & Design module
in the University of Central England
By : Harry Sufehmi, student id #98799231
Abstracts: This report contains technical comparisons of
several solutions for Tunnup's need of a computerised stock
control system. A recommendation is given for the best
solution.
TABLE OF CONTENTS
-----------------
1. Executive Summary
2. Introduction
3. Discussions of solutions
I. The base hardware needed
II. The solutions
a. Barcode system
b. DataNet's wireless barcode system
3. Conclusions
4. Bibliography
EXECUTIVE SUMMARY
-----------------
Tunnup Cycle had turned to us for their need of a good
stock control system. To be able to implement the solution,
first we must select the right technology. This report
discuss the technical feasibility survey done to accomplish
that.
The report consisted of discussion of the solutions,
and then finished with a recommendation.
At first we did a pre-survey. In this stage, we set a
basic requirements, and then browse quickly through all of
available solution. Only the ones passed this stage then
chosen to be included in this report, and scrutinised
further.
The recommended solution for Tunnup Cycle is wireless
barcode system. The lack of cabling in this solution makes
it very ideal for a factory environment, and also enhances
its reliability. Also although the component prices are much
higher, but since we don't need workstations to attach it
into, we also save a lot. Thus the final cost is a little
bit lower than the conventional barcode system.
INTRODUCTION
------------
Tunnup Cycles have been experiencing growth in
exponential curve. More, and more people prefers free
lifestyle. This perfectly fits the image of motorcycles
produced by Tunnup, resulting in high demand for them,
especially for the Adventurer series. Also the fact that its
consumer comes from very wide range of age helps too, from
17 years old teenager to 57 years old senior. But along with
the success, other problems appears.
One of the problem is related to a technical aspect,
inventory control. High demand means it needs to produce
more motorcycles. More motorcycles means more inventories.
More inventories demands good management, or else the
company could suffer badly from a lot of problems.
Including, but not limited to, problems like idle stock
(overstocked), or understocked, loss of goods due to
security problem, the lack of ability to track parts around
the factory, items unavailable when needed, etceteras -
which all leads to one conclusion, loss of profit.
Tunnup Cycles have recognised this from early on. Thus
they turn to us for the solution of this problem. After
several meetings, we started to do some surveys.
In this report, we provides the result of the survey
from technical perspective. We compare solutions, and then
pick up the best to be implemented in Tunnup Cycles.
DISCUSSION OF SOLUTIONS
-----------------------
In this chapter, we will discuss all of the solutions
that we have surveyed. Please note that before the survey
itself, we did a pre-survey assessment. Only solutions that
passes all of our considerations in the pre-survey stage
will be researched in depth, and discussed in this report.
I. The base hardware needed
Of all the solutions discussed here, all of them need
the same hardware base. This is simply because those
hardware is essential for the inventory control system.
The base hardware requirements is:
1. 1 main server (estimated price: £ 2500)
2. 1 standby backup server (estimated price: £ 1500)
3. 1 tape backup drive (estimated price: £ 500)
4. 1 UPS (Uninterruptible Power Supply) (estimated price: £ 750)
2 servers would be needed. The first would act as the
main server. The second would act as the backup server.
Whenever the main server is down, the backup server would
automatically take over control and start serving the
network immediately.
The tape backup drive would backup Tunnup's data
periodically. This way, even if both of the server goes down
with the data, Tunnup will still have the backup, and could
be back to operation again in as little time as possible.
The UPS (Uninterruptible Power Supply) is simply
essential. In the event of power failure, the system
administrator will still have chance to shutdown the
computer system gracefully, avoiding the risk of data
corruption.
II. The Solutions
II.a. Barcode system
SUMMARY OF EQUIPMENTS
1. 8 Barcode reader (total estimated price : £ 3200)
2. 1 backup Barcode reader (estimated price : £ 400)
3. 1 Barcode printer (estimated price : £ 1000)
4. 8 Computer workstations (total estimated price : £ 6000)
5. 1 backup Computer workstation (estimated price : £ 750)
6. 11 Network interface cards (NIC) (total estimated price : £ 550)
7. 1 backup NIC (estimated price : £ 50)
8. 1 Network hub - 24 ports (estimated price : £ 350)
9. 1 backup Network hub (estimated price : £ 350)
10. Shielded Twisted Pair (STP) cable (total estimated price : £ 100)
11. 50 pieces STP connector (total estimated price : £ 50)
12. 1 STP connector maker (estimated price : £ 25)
13. Installation labour & costs ( : £ 1440)
(at rate of £ 45 per hour, working for 4 days)
TOTAL ESTIMATED COST : £ 19,515
(including the base hardware required)
Explanation of the system
The first thing that comes to our mind when we think about
this project is a barcode system. That is only natural,
because a barcode system is fast, reliable, very easy to
use, and a proven system that has been used for years.
At the list above, we include 1 backup for every type of
device. This way, when a device can't be operated, the user
could still continue working using the backup device. In the
mean time, we will get the replacement, which could take
about 2-3 days to arrive here. We shall avoid downtime
whenever possible.
The barcode reader would be attached to the PC workstation
via the RS-232 connector, also know as serial port/COM2. The
input will be received by the software running in the
workstation, which in turn will access the server.
The barcode printer is attached to the PC workstation
located in the counter. Every parts received from the
supplier will goes there first. Each will be given the
corresponding barcode label.
For the local area network (LAN), we will need to equip
every PC with a network interface card. All 8 workstations
and the 2 servers. Then we will need to connect every PCs.
The cable will be laid out to all of the detector points.
Then all of the cable will be connected to the main network
hub, so all of the PCs could talk to each other.
But we must note here,
that using cable in a factory have the potential to unveil
several new problems.
First, we will have to install the cable first. This will
require experts in this field, since faults in the initial
cabling installations could cause a lot of money spent later
for the troubleshooting.
Second, the cable installation itself will need quite a lot
of time. This is because at first we will have to install
the cable racks first. We will pull the cable up to the
roof, then the cable would descent back to the PCs or to
the network hub. This way we avoid cluttering the factory
floor, in the expense of time (and some amount of additional
costs).
Third, using cable limits the moveability of the detector
station. PCs could be moved easily, but the network cable
can't. It adds some delay, and interruptions to the working
staff, whenever a move of a detector point is requested, due
to some purging and re-installations that must be done.
Fourth, and perhaps is the biggest issue, using cable in the
long run could introduce a lot of problem, because 70% of
Local Area Network problems are related to cabling. From our
previous experiences, we heartily agree with this statement.
To prevent this, we'll have to be very strict from the
beginning; use only the expert installator, documents
everything, insist on top quality components, etceteras.
As the result, cost could escalate, and yet there are still
possibility that the problem still happens later - only
reduced in probability.
Considering all of the pitfalls above, we were forced to
search for another alternative solution.
II.b. DataNet's wireless barcode system
SUMMARY OF EQUIPMENTS
1. 1 DNT 540R - data collector (estimated price : £ 650)
2. 1 DNT 540R - backup (estimated price : £ 650)
3. 8 Telxon PTC-960SL - wireless barcode reader (estimated total price: £ 6800)
4. 1 Telxon PTC-960SL - backup (estimated price : £ 850)
5. 1 DNP 4100 barcode printer (estimated price : £ 1000)
6. 1 Computer workstation (estimated price : £ 750)
7. Cabling cost (estimated cost : £ 75)
8. Installation labour & costs ( : £ 360)
(at rate of £ 45 per hour, working for 2 day)
TOTAL ESTIMATED COST : £ 16,550
(including the base hardware required)
Explanation of the system
DataNet Corp is a group of experienced people in inventory
control system. They provides both the software and the
hardware.
The products is based on barcode technology. But, they
perfected it by introducing rugged and portable (hand held)
wireless barcode reader, using Spread Spectrum Radio link as
the communication media; effectively eliminating the needs
for cabling to every workstation.
Even though the cost of cabling is not substantial, the
biggest advantage of this wireless barcode reader is in its
flexibility. Workers are not limited by their workstation
placements anymore. More flexibility means more
productivity.
Also, it have to be remembered that 70% of Local Area
Network problems are related to cabling. So by eliminating
the cable, we have highly increased the stability of the
network = less downtime, more productive work.
The hand held reader provides advanced error-recovery
technique, so the communication link won't be destroyed even
under extreme factory situation. The system also provides
manual override. Coupled with a lot of memory in each
device, they could operate (estimated) for up to 2 days
without the network available.
The following products have been examined and recommended:
1. Bar code printer (DNP 4100)
We'll still need one computer workstation to be connected to
this printer. But that's it.
This printer is highly rugged, tested, built for use in
rough factory condition.
This printer will need to be attached to a workstation. So
we'll need 1 workstation, which will be put in the parts
reception counter, to attach this into. That's why again
that there is a cabling cost in this solution, because we'll
need to connect the workstation to the server via ordinary
network cabling system.
2. Telxon PTC-960SL - Laser scanning wireless mobile computer.
This is the handheld barcode reader.
Compact, easy to use, no hassle. Yet configurable and pack
quite a lot of processing power, thanks to the dual 80C88
microprocessors. Weighting in just 0.737 kg (including
battery and RF comm link), with ability to withstand up to
50oC operating temperature and shock from being dropped from
1.2 m high; this is the ideal barcode reader for Tunnup. And
remember, it eliminates the need for computer workstations
and cabling - saving the workstation purchasing cost and
cabling maintenance cost.
3. DNT 540R - Portable Radio Frequency Data Collection Terminal
This equipment is where all the data from the barcode
reader is received. Could be connected to the main server
directly, a single device could serve up to 128 barcode
readers.
CONCLUSIONS
-----------
From all of the discussions of the solutions above, it
is easy to conclude that DataNet provides the best solution
for Tunnup Cycles' needs.
It is easy to install, specified to perform in rough
environment, effectively eliminate the need for workstations
and cabling, fast, and easy to maintain.
To top it off, DataNet's solution is even cheaper than
conventional barcode system solution. This is primarily due
to the elimination of the PC workstations, since now we
could use just the wireless barcode reader instead.
Therefore, it is highly recommended for Tunnup to
deploy it in its factory. We will contact DataNet regarding
this, and will collaborate to provide all of the technical
assistance needed to get the system up and running in the
shortest time possible.
ASSUMPTIONS
-----------
This report was written upon the following assumptions:
1.A pre-survey was done before the technical feasibility
survey itself conducted. In this phase, a lot of possible
solutions were gathered, and quickly assessed.
This is because there are simply too many solutions
available from too many vendors, that
complete technical feasibility survey on all of them would
make this project never be
completed and will require an astronomical amount of
research budget.
Only the ones that fulfil the following criteria will then
be entered to the technical feasibility
survey. The criteria were set as:
# Easy to use:
The users were assumed to be normal ordinary people, so
easy of use is a very essential
factor if we want to get the job actually done quickly.
# Able to operate in harsh environment:
We assume the factory is a very harsh environment for the
electronic devices, because
of the possible differences in heat, and/or the various
chemicals used in there (especially
for the painting/stainless-steel purifying purpose) , and
also especially all of the
electronic interferences making it hard for a below-
standard network equipment to
function properly.
# Reliable:
We assume that the device will receive a lot of shock;
from mishandling, vibrations,
etceteras.
# Priced within budget allocated by Tunnup.
2.The budget allocated by Tunnup (not including the
consultation fee, just for the cost of software, hardware,
and installation fees) is assumed to be £ 25,000
3.The time given by Tunnup to implement the solution is 3
months.
4.The computer hardware used will be using Intel-based
architecture (IBM-PC compatible)
This is to ensure easy upgrade path and easy maintenance,
since there are more computer
consultants available that could handle problems with Intel-
based machines than for other
platforms.
5.Therefore, the software used will be the ones that is
Intel-compatible too.
6.All hardware comes with:
# 1 year replacement warranty
# 2 years service-only warranty
7.The software comes with lifetime warranty
8.The cost of the software is included in the hardware
price.
BIBLIOGRAPHY
------------
1. J. Flynn, Donald (1992),
Information System Requirements: Determination and Analysis,
McGraw-Hill
2. Factory tour of Triumph Motorcycle, Leicestershire
3. Interview with Mr. Rob of Triumph Motorcycle
4. http://www.datanetcorp.com/
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Last modified: 27 February 1999