Zone 4 Systems Integration and Design (“Zone 4”) a leader in the installation of automated storage and retrieval systems, advanced material handling and rack storage systems servicing the retail, e-commerce, logistics, and grocery sectors nationwide. Headquartered in Orange, CA, the company’s core base of blue-chip customers leads the world in automated warehouse logistics. Zone 4 delivers unparalleled expertise implementing automated storage/retrieval systems (AS/RS), multi-shuttle, and mini-load systems in the rapidly expanding e-commerce and food delivery markets.
LOCATION
Orange, CA
CONTRACTOR TYPE
Specialty Contractor
TRADE
Mechanical / Electrical
INTEGRATIONS
Mechanical and Electrical Contractor Transforms Time Tracking Efficiency and Accuracy with SmartBarrel
Zone 4 is an installation deployment expert specializing in mechanical, electrical, for solutions including ASRS, MHE equipment, robotic solutions, racking and labeling applications. They work with companies that range from Fortune 10 to fast growing organizations in multiple industries. Zone 4 is a nationwide leader in installation of automated storage and retrieval systems, advanced turnkey material handling, robotic cells, rack storage systems and label installations servicing the retail, e-commerce, logistics, and grocery sectors nationwide.
Prior to contracting with SmartBarrel, Zone 4’s employees and subcontractors had to clock in and out using paper timesheets.
"After deploying SmartBarrel, we've eliminated an entire headcount that just managed our timesheet process, making the time clock in 3 times faster for every one worker each day – saving nearly 1,400 hours a year based on a more efficient process. We also now pay our subs up to 4 times faster – increasing their desire to work with us."
- Jordan Deal, Project Controller at Zone 4.
BEFORE SMARTBARREL
The Painful Paper Nightmare
Before SmartBarrel, Zone 4 used paper timesheets to sign their employees in and out on every job site. “Relying on paper timesheets was a constant headache. Not only is manual tracking more prone to errors and misplacement, but also slowed down payment processing and created unnecessary administrative burdens. The cost of managing manual paper timesheets—including the time spent on corrections, approvals, and payroll processing – added up to a significant material cost to the company.”
Previously, their payroll process involved 6 steps:
- Every employee signed in on a paper timesheet
- The foreman adjusted, verified, and approved the times
- A project admin would copy the sheet into Excel
- The timesheet hours were sent to the subcontractors and temporary labor agencies
- The subs and agencies would submit an invoice
- Zone 4 would pay the invoice
Beyond the obvious challenges that come from manually tracking timesheets, accurately tracking labor hours and forecasting project costs were very challenging given the time this data took to compile, reconcile and upload. Jordan said, “Before SmartBarrel, forecasting labor and project timelines was challenging. We had to rely on manual entries and paper timesheets making it incredibly difficult to quickly predict project completion dates and resource requirements.”
THE RESULTS
The Texan Pilot
Starting with a single pilot job site in Texas, Zone 4 deployed SmartBarrel and quickly realized:
- Accurate labor hours with Smart Barrels 100% accuracy on time tracking so that workers were paid up to the minute worked
- Reduced clock in and out time from 15 seconds to 4 seconds per worker
- Eliminated Risk of Time Theft and Reduced Foremen Review Time with SmartBarrel’s biometric facial verification of each worker to ensure accuracy
- Better Reporting and Forecasting with all the SmartBarrel time data automatically synced to Procore after verification
Within a month, Zone 4 knew they needed SmartBarrel on every job site moving forward.
"Our Texas pilot was a game-changer. We were able to see firsthand how SmartBarrel could streamline our processes and provide real-time data. The immediate improvement in efficiency and accuracy convinced us that this was the right solution for all our projects."
One hidden gem was SmartBarrel’s ability to ensure workers were able to clock in prior to the start of their shift, but automatically adjust to reflect their scheduled start time allowing for a more streamlined clock in process.
Revolutionizing the Process
SmartBarrel transformed Zone 4’s subcontractor payment process by reducing time spent on the process by over 75%. The foreman approved timesheets from the previous work week on Monday morning and uploaded them that afternoon. The subcontractors and temporary labor agencies also received the hours worked on Monday, and their invoices were received back on Tuesday. Zone 4 paid the invoices on Friday. Jordan says, “Switching to SmartBarrel revolutionized our subcontractor payment process. What used to take us over a week is now done in 5 days. The efficiency and accuracy of the system have saved us an incredible amount of time and resources.”
THE IMPACT
Continuous Streamlined Improvement
The impact of SmartBarrel on the culture at Zone 4 has been monumental. Employees and subcontractors now experience a streamlined process that fosters transparency, boosting morale and trust in the system. Eliminating manual errors and accelerating payroll processing has invigorated the workforce, driving productivity and job satisfaction to new heights. This technological upgrade has nurtured a culture of efficiency, accuracy, and mutual respect within the organization, setting Zone 4 apart as an industry leader in innovation and workforce empowerment.
"Switching to SmartBarrel revolutionized our subcontractor payment process. What used to take us over a week is now done in 5 days. The efficiency and accuracy of the system have saved us an incredible amount of time and resources."
The most accurate time clock in construction.
Powered by biometrics and AI, SmartBarrel completely automates time tracking and guarantees 100% accuracy.
