ADI Logistics Moves to Ruckus Smart WLAN Meshing to Increase Warehouse Efficiency
ADI Logistics (ADI) had dabbled with Wi-Fi and found the experience less than exciting. Having sprinkled some consumer-grade access points wherever there was an Ethernet drop, ADI couldn't get Wi-Fi signals where they needed them within their massive 185,000 square foot warehousing facility in Edison, New Jersey.
ADI provides over one hundred manufacturers, importers and distributors with distribution, storage, freight and trucking services throughout the United States - serving a wide range of markets, from office and medical suppliers to electronics, apparel and sporting goods. Having a reliable and ubiquitous Wi-Fi network to track inventory movement, support back office applications and provide guest and employee access was essential to operational productivity.
But a number of problems kept ADI from successfully deploying a wireless LAN. A hostile RF environment, lack of Ethernet cabling and the sheer size of its facilities made deploying a production-quality WLAN seem impossible.
"It's a tall task, deploying Wi-Fi in any warehousing plant, due to the sheer size of the facility and the difficult environmental conditions that exist," said Lou Schmaus, MIS Director at ADI Logistics. "There is a lot of metal in the way of Wi-Fi signals and hardly any Ethernet cabling available in these facilities, so finding a wireless LAN system that could cope was turning out to be a pipe dream."
ADI needed the Wi-Fi network to support staff with ruggedized mobile devices accessing ADI's inventory database. ADI also wanted to offer more options to its customers, many of whom bring their own computer systems, software and network requirements. "Things are always changing with respect to networking in the warehouse, which is why Wi-Fi was essential," said Schmaus.
ADI promotes the fact that they don't have a fixed warehouse setup. As new customers come in that require different floor racks or re-arrangement of the warehouse layout, ADI can quickly adjust to meet their needs. Wi-Fi connectivity is key to maintaining the flexibility that has become a major selling point for ADI.
ADI has been planning to install a new warehouse management system that provides a real-time view of inventory. ADI's vision has been to leverage wireless technology to remove the manual paper flow that slows operational efficiency. "We desperately needed to light up the entire warehouse so that every time an item is moved, we could scan a barcode and send that information immediately to our system instead of waiting for paper to flow," said Schmaus. And ADI wanted to provide controlled guest access for customers and vendors.
Previously ADI had deployed several Linksys 802.11g APs and wireless bridges, but quickly encountered coverage, performance and reliability issues. "We just weren't comfortable that the existing Wi-Fi system was going to be able to handle our new inventory management application." ADI was putting in up to 20 new packing stations in a remote location of the warehouse. These stations were a minimum of 400 to 500 feet away - too far for a standard Ethernet run and too expensive to cable.
"This facility is a nightmare for wireless given its size and construction. And with limited Ethernet wiring, being able to deploy a production class wireless LAN was beginning to look impossible.
By combining high gain smart antennas and wireless meshing, the Ruckus ZoneFlex system changed everything for us.
For about one third the cost of alternative WLANs we considered, the ZoneFlex system has given use complete and reliable coverage with the fewest number of APs and without additional Ethernet cabling."
Lou Schmaus
MIS Director
ADI Logistics, Inc.
According to ADI, to solve these problems and meet the distinct requirements of their warehouse environment, they selected the Ruckus Wireless ZoneFlex Smart WLAN solution for five fundamental reasons:
1. Flexibility
With the Smart Meshing capability, ADI was able to place APs wherever they needed without the cost, time and hassle of pulling Ethernet drops
2. Reliability
With each AP integrating an adaptive antenna array that can focus RF energy where needed and steer it over the best performing paths, ADI was assured wire-like reliability.
3. Range
The ZoneFlex Smart WLAN system offered integrated high-gain antennas in every APs, so fewer APs were required and better coverage was achieved.
4. Ease of use
The ZoneFlex system was configured in minutes and installed across the entire warehouse in under four hours.
5. Cost
The ZoneFlex system was about one-third of the cost of other WLAN alternatives that ADI considered.
Multiple SSIDs on each ZoneFlex AP lets ADI provide secure and controlled Wi-Fi access to guests and encrypted/authenticated access to staff. The simple guest pass feature on the Ruckus ZoneDirector allows unique guest passes (along with an associated access codes) to be dynamically generated and printed. A time limit for each guest pass can be assigned in minutes, hours or days.
Smart mesh ZoneFlex 2942 802.11g APs were deployed 42 feet high in the ceiling of ADI's warehouse without having to run Ethernet cabling. Once plugged into the power source, the APs automatically form the best network topology, self configure and self optimize as things change.
"This is a big-time money saver for us," said Schmaus. "We got this done for about one-tenth the cost of other wireless solutions we had priced out. With ZoneFlex, we could run a robut wireless LAN without running more Ethernet cables."
According to ADI, other WLAN systems dictated two to three times more APs, each requiring an Ethernet connection. "When you're talking about APs 42 feet in the air within a 185,000 square foot facility, this just didn't make operational or economical sense," said Schmaus.
"The hardest part of the install was getting the scissor lift directly underneath the place where we needed to mount the AP," Schmaus concluded.
- Company Overview
Located in Edison, New Jersey, ADI Logistics (ADI) is a just-in-time logistics company with expertise in distribution, freight and trucking services throughout the continental United States. Serving over a hundred manufacturers, importers and distributors, ADI operates a 185,000-square-foot logistics facility.
- Requirements
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- Deploy a centrally-managed WLAN that was simple to administer
- Minimize the number of APs
- Provide complete Wi-Fi coverage for warehouse and business space
- Eliminate any additional Ethernet cabling throughout facility
- Employ a Wi-Fi system that operates reliably within a hostile RF environment
- Offer controlled guest access
- Solution
- Benefits
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- Reduced Wi-Fi network administration
- Eliminated any additional costs associated with running Ethernet cable to support Wi-Fi access points
- Gained complete coverage, with half the number of AP proposed by other Wi-Fi vendors
- Eliminated Wi-Fi coverage gaps/holes
- Streamlined deployment allowed entire WLAN to be installed and operational in under four hours
- Improved user experience
- Adaptable Wi-Fi signals allow reliable coverage within hostile RF environment
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