Case Study: Inventory Accuracy with Hyperion LiDAR
An in-depth analysis of how Hyperion's scanning technology transforms inventory management at our clients RMX plant, revealing significant discrepancies and demonstrating a tangible return on investment against traditional ticketing methods.
The Challenge at Ocala RMX Plant
High material throughput: Frequent deliveries and draws complicate tracking.
Multiple aggregate types: Need for precise monitoring for each material type.
Operational complexity: Constant balance between theoretical, physical, and production inventory needs.
A High-Volume Environment
This RMX is a high-volume ready-mix concrete plant that handles a constant flow of limestone and sand. The rapid turnover of these materials presents a significant challenge in maintaining an accurate inventory. The exclusive reliance on truck tickets for inventory tracking introduces variables such as moisture, scale calibration, and material flow inconsistencies, which generate costly discrepancies.
This dynamic environment served as the ideal testing ground to evaluate an advanced measurement solution like Hyperion, where the precision of LiDAR-based scanning could be directly compared to ticket-based accounting to uncover inefficiencies and improve decision-making.
Comparison: Ticketing System vs. Hyperion
| Category | Traditional Ticketing System | Hyperion Scanning System |
|---|---|---|
| Accuracy | Depends on truck scales, subject to calibration errors, moisture changes, and loading inconsistencies. Variations can accumulate over time. | Promotes accuracy within 5%. Control tests showed a 4-6% variation against tickets. Provides consistent volumetric measurements. |
| Financial Impact | Discrepancies can lead to tens of thousands of dollars in hidden losses. Example: March-April 2025 ticket gaps exceeded $160,000. | Identifies discrepancies between theoretical, physical, and scanned inventory. Protects against financial leakage and improves accountability. |
| Consistency | Dependent on operators, truck flow, and ticket entry. Variability between different sites. | Automated scans ensure consistent and unbiased data every time. |
| Scalability | Scales and tickets are local, not easily standardized across multiple facilities. | Cloud-ready. Integrates with SAP, JD Edwards, Domo, and scales easily across multiple sites. |
Data Analysis: Inventory Measurement
Over a three-month period, theoretical, physical, and Hyperion scan data were compared. The charts below illustrate the notable discrepancies that Hyperion was able to identify, providing a much more accurate view of the actual inventory on site.
Inventory Comparison - March 2025
Inventory Comparison - April 2025
Inventory Comparison - May 2025
Gain/Loss Analysis - May 2025
Hyperion Cost Analysis
Initial Investment
The total initial cost for Hyperion implementation is $6,600.00. This amount covers all necessary hardware, network setup, installation, and the first month of service.
Recurring Costs
Ongoing operational costs are predictable and affordable, ensuring constant and accurate inventory monitoring.
Control Tests and Accuracy
To validate Hyperion's accuracy, two isolated control tests were conducted. These tests compared the amount of material recorded by truck tickets with Hyperion scans before and after deliveries. The results demonstrate remarkable consistency and precision.
Control Test 1 (05/08/2021)
Tons Registered (Tickets): 81.16 st
Hyperion Scan: 76.23 st
Difference: 4.93 st (6%)
Control Test 2 (05/21/2025)
Tons Registered (Tickets): 85.82 st
Hyperion Scan: 82.3 st
Difference: 3.52 st (4%)
Conclusion: A Clear and Measurable Advantage
The study at the Quikrete Ocala RMX plant conclusively demonstrates the advantages of Hyperion over traditional ticketing systems. While ticket-based management is prone to cumulative errors, Hyperion provides direct, high-precision measurements that reflect the true state of inventories. This consistency not only increases confidence in reports but also reduces costly discrepancies, streamlines reconciliation, and allows for more proactive decision-making.
By adopting Hyperion, operations like Quikrete gain a scalable and reliable inventory tracking method that surpasses the ticketing system in both accuracy and efficiency, transforming inventory data into actionable business intelligence.
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