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You've optimised the production line. But what about everything around it?
Manufacturing businesses invest heavily in production efficiency. Line speed, unit cost, waste reduction — all measured, monitored and continuously improved.
But in goods receipt, picking, storage and despatch, a different kind of waste is happening every single day. One that rarely appears on a report. One that most operations have quietly accepted as unavoidable.
At every shift start, workers queue to collect their shared Zebra device. Someone manually checks it out. Logs a name. Hands it over. Multiply that across every worker, every shift, every day — and you're losing tens of thousands of pounds a year before a single item has been picked or packed.
That's before you factor in missing devices, failed batteries and an IT team spending hours tracking down equipment that should never have gone missing in the first place.
Four costs quietly draining your manufacturing operation every day.
Most operations know they have these problems. Few have calculated what they actually cost.
1. Shift start queues and manual check-out
Every worker queuing to collect a device at shift start.
2. Missing and lost devices
Manufacturing operations typically lose between 5% and 8% of their rugged device estate every year.
3. Batteries failing mid-shift
A device can show fully charged at shift start and still die two hours later if the battery is old.
4. Zero accountability for shared devices
When nobody knows who has which device, nobody takes responsibility for it.
Automated device issuing — no queues, no manual process: Waizu Identity automates the entire check-in and check-out process. Workers tap their NFC building access badge or enter a PIN and the device is instantly assigned to them — no manual logging, no dedicated member of staff, no queue. Sub-2-minute handovers across every shift, every day.
Real-time location and proactive missing device alerts: Waizu Traceability tracks every device continuously via Wi-Fi, GPS and BLE beacons. The moment a device enters an unauthorised zone, stops reporting, or isn't returned at shift end, the right person is alerted instantly — via Teams, Slack or email. You know about the problem before your team reports it.
Battery charge and health monitoring: Waizu displays battery charge level and battery health on every device before it's picked up. Workers always grab a device with enough charge to last the full shift. Managers can see which batteries are degrading and replace on a need-to-replace basis — eliminating blanket replacement cycles and reducing unnecessary cost.
Personal accountability at every shift: Waizu Identity forces every user to log in before a device can be used. Every device is tied to a named individual from the moment it leaves its home location. Workers become accountable for the equipment they carry — and behaviour changes as a result. Device damage falls. Loss falls. And when something does go wrong, you know exactly who had it last.
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£50,000 = Annual productivity cost of 8-minute shift delays in a 100-device estate — eliminated by automated device issuing
5-8% = Typical annual device loss rate in manufacturing — reduced to under 2% with Waizu Identity and Traceability
90% = Reduction in device-related IT support tickets — based on SEKO Logistics UK benchmark
17-20 weeks = Typical payback period for a manufacturing operation deploying Waizu