DESIGN AND IMPLEMENTATION OF A TRACKING SYSTEM FOR WARRANTY RETURNED PARTS IN AUTO BAVARIA BALAKONG STORAGE ROOM

TECHNICAL REPORT INDUSTRIAL FINAL PROJECT MMT32510 Name : MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Matric Number : 221543713 Faculty & University : FACULTY OF MECHANICAL ENGINEERING & TECHNOLOGY UNIVERSITI MALAYSIA PERLIS University Supervisor : TS. DR. ING. MOHD NAZRI BIN OMAR WBL Company : AUTO BAVARIA BALAKONG Industrial Coach : HAMIZAN BIN BAYRI @ MD KHARI Report Number : UNIMAP/FKTM/P3/221543713 Project Title: DESIGN AND IMPLEMENTATION OF A TRACKING SYSTEM FOR WARRANTY RETURNED PARTS IN AUTO BAVARIA BALAKONG STORAGE ROOM Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 3 of 30 Table of Contents 1 EXTENDED ABSTRACT 5 2 INTRODUCTION 6 2.1 Background Information 6 2.2 Relevance and Importance 6 2.3 Significance of the Study 7 3 PROBLEM STATEMENTS 8 3.1 Identification of the Problem 8 3.2 Significance of the Problem 9 4 OBJECTIVES 10 4.1 Project Objective 10 4.2 Alignment with Problem Statement 11 4.3 Expected Outcomes 11 5 SCOPES 11 5.1 Report Boundaries 11 5.2 Limitations 12 5.3 Assumptions 12 5.4 Significance of the Scope 12 6 METHODOLOGY / WORK PROCEDURE 13 6.1 Report Design 13 6.2 Data Collection Methods 13 Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 4 of 30 6.3 Data Analysis Techniques 14 6.4 Materials and Equipment 15 6.5 Procedural Steps 16 7 RESULTS 16 7.1 Data Presentation 16 7.2 Analysis 17 7.3 Key Findings 18 7.4 Comparative Analysis 19 7.5 Unexpected Outcomes 20 8 DISCUSSION 21 8.1 Interpretation of Results 21 8.2 Implications 22 8.3 Comparison with Existing Literature 23 8.4 Limitations 24 8.5 Recommendations 25 9 CONCLUSION 27 10 REFERENCE 28 11 APPENDICES 30 Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 5 of 30 1 EXTENDED ABSTRACT This project focuses on the design and implementation of a manual tracking system to improve the management of warranty-returned parts at Auto Bavaria Balakong, an authorized BMW dealership and service center operated by Sime Darby Motors. The existing method of writing details directly on parts with markers is unreliable as information often fades, becomes unreadable or incomplete, causing delays in retrieval and risks of non-compliance with BMW audit requirements. The objective of this project is to introduce a structured system that ensures accuracy, traceability and efficiency in part management. The proposed solution includes standardized printed tags containing essential details such as chassis number, part number and date of replacement, securely attached to parts with cable ties, along with a Microsoft Excel tracking file where technicians must enter the same information before placing items in storage. Data collection involved interviews with warranty staff and the head of the warranty department, as well as direct observations in the storage room. The findings revealed frequent issues with missing or unclear labels and average retrieval times of about five minutes per part, highlighting inefficiencies in the current system. The proposed tagging and Excel-based method was evaluated against these challenges and is expected to reduce retrieval time to one to two minutes, improve data accuracy and strengthen compliance with manufacturer requirements. The scope of the project is limited to internal handling of warranty-returned parts in the Balakong storage room and does not extend to long-term tracking after parts leave the facility. Limitations include reliance on technician discipline to follow procedures and the possibility of human error in manual data entry. Despite these constraints, the project provides a practical, low-cost and effective solution using existing resources, with significant benefits for efficiency, compliance and service quality in after-sales operations. Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 6 of 30 2 INTRODUCTION 2.1 Background Information Auto Bavaria is a well-known authorized BMW dealership and service center operated by Sime Darby Motors. The service department performs numerous warranty-related part replacements as part of BMW after-sales support. These replaced parts must be stored temporarily for return to BMW or future verification during audits. Currently, technicians label these returned parts by manually writing on them using markers. This informal method is inconsistent and prone to fading or illegibility over time. Furthermore, there is no centralized system in place to verify that a part has been properly stored or logged, causing issues when parts need to be retrieved (Nurcahyo et al., 2019). 2.2 Relevance and Importance Efficient management of warranty-returned parts is essential in the after-sales service industry. At Auto Bavaria, these parts must be stored for possible inspection or audit by BMW. However, the current labeling method is inconsistent and unreliable. Writing directly on parts using markers often results in faded or unreadable information which makes it difficult for staff to identify or locate parts when needed. This issue affects the speed and accuracy of part retrieval especially when specific items are requested for warranty verification. Delays in locating parts can disrupt daily operations and lead to non-compliance with manufacturer requirements. These problems reduce productivity and risk damaging the workshop’s reputation with the principal brand (Harris, 2019; Nurcahyo et al., 2019). Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 7 of 30 2.3 Significance of the Study The introduction of a structured tagging system along with a centralized Excel tracking file is relevant to address these challenges. It ensures returned parts are properly labeled, recorded and easy to locate. This solution supports better coordination between technicians and the warranty department while improving the overall efficiency of the storage process. The study focuses on solving a practical problem faced in the day-to-day operations of Auto Bavaria warranty department. As one of the key players in the luxury automotive sector, Auto Bavaria must maintain a high standard of service quality and efficiency. One area that impacts service quality is the management of warranty-returned parts. If a part cannot be located promptly when BMW requests it, this reflects poorly on the service center and may result in administrative delays or failed audits. This study is significant because it introduces a simple and practical system to prevent such issues (Sharma & Bhatia, 2018; Singh & Pandey, 2015). By requiring technicians to attach a clear tag with essential information and to enter the same data into an Excel file before placing the item into storage, the process becomes more structured. The warranty department can quickly confirm whether an item is stored and locate it without needing to physically search through unmarked items. Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 8 of 30 3 PROBLEM STATEMENTS 3.1 Identification of the Problem Auto Bavaria handles a large volume of part replacements under the BMW warranty program. Once replaced, these faulty parts are stored in a designated area for inspection, return or audit purposes. However, the current tracking method used by technicians is inconsistent and inefficient. Most technicians write information such as the chassis number, date of replacement and part number directly on the part using a marker. This method is unreliable because the writing often fades or becomes unreadable over time. In many cases, the information written is incomplete or not standardized. Figure 1: Part labelled using marker with faded and unclear writing When the warranty department or BMW requests a specific returned part, staff often face difficulties locating it. This results in delays, frustration and wasted effort. The lack of a centralized record also prevents verification of whether a part has been stored properly. These issues reduce productivity and increase the risk of miscommunication between departments (Sharma & Bhatia, 2018). Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 9 of 30 Figure 2: Staff searching for a returned part 3.2 Significance of the Problem An ineffective tracking system can lead to misplaced parts, slower response times and potential non-compliance with BMW audit standards. Failure to produce requested parts when needed could affect claim approvals or cause reputational harm. This problem is significant because it impacts the credibility of the service center and disrupts workflow. Implementing a structured tagging system supported by an Excel-based tracking file offers a practical solution. It ensures each part is traceable, verifiable and easier to retrieve (Nurcahyo et al., 2019; Singh & Pandey, 2015). Addressing this problem is essential to maintain service quality and operational efficiency. Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 16 of 30 7 RESULT 7.1 Data Presentation Method Existing Process Improved Process Average Search Time per Part 5 minutes 1-2 minutes Accuracy of Information Often incomplete/faded Consistent and clear Labeling Method Marker writing Printed tag + Excel log Storage Condition Random placement, inconsistent Organized, verified with Excel Figure 5: Existing warranty part handling process Figure 6: Improved warranty part tracking process Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 17 of 30 7.2 Analysis The analysis of the collected data shows a clear difference between the old tracking method and the proposed tagging and Excel system. Previously, technicians wrote important details like the chassis number, part number and date of replacement directly on the part using markers. Over time, this writing often faded or became unclear, making it difficult for warranty staff to identify or locate the correct item. On average, it took around five minutes to find a single part, which slowed down daily work and created risks during BMW audits. With the new system in place, several improvements were noticeable. Standardized tags were attached to every returned part using cable ties, ensuring the information stayed clear and consistent. At the same time, technicians were required to update an Excel file before storing the part. This gave the warranty department a centralized record that could be checked instantly without the need to dig through shelves. As a result, the retrieval time dropped to just one to two minutes. The new method also improved accuracy and communication. Since the tags and Excel log contained the same details, the chance of missing or incomplete information was much lower. The dual system acted as a safeguard: the physical tag made it easy to identify the part in storage, while the Excel log provided a quick reference to confirm details. Together, these changes increased efficiency, reduced mistakes and improved the traceability of warranty-returned parts. Overall, the analysis confirms that the new tagging and Excel system solved the main weaknesses of the old approach. It made parts easier to identify, faster to retrieve, more reliable for audits and helped technicians and warranty staff work together more effectively. Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 18 of 30 7.3 Key Findings The analysis of the data highlights several important findings about the management of warranty-returned parts at Auto Bavaria Balakong. The first finding is that the existing system of writing details directly on parts with markers is not effective. The markings fade or become unclear over time, leading to incomplete or inconsistent identification. This problem increases the time needed to find parts and often causes delays during warranty audits or inspections. The second finding is that introducing a structured tagging system together with an Excel-based tracking file offers a practical and cost-effective improvement. The use of printed tags ensures that critical information such as the chassis number, part number and date of replacement is always recorded in a clear and legible format. Attaching the tags with cable ties further reduces the risk of details being lost or damaged. The third finding is the benefit of requiring technicians to update the Excel file before storing the parts. This step creates a reliable centralized record that warranty staff can check quickly without carrying out lengthy searches. As a result, the time taken to retrieve specific parts has dropped from an average of five minutes to between one and two minutes, clearly demonstrating greater efficiency. Finally, the project has strengthened communication between technicians and the warranty department. The combination of physical tags and digital records improves accuracy, traceability and accountability in managing returned parts. This not only streamlines internal processes but also supports better compliance with BMW requirements during audits (Singh & Pandey, 2015). Overall, these findings confirm that the proposed system effectively addresses the weaknesses of the old process while adding value by improving efficiency, reliability and compliance in handling warranty-returned parts. Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 19 of 30 7.4 Comparative Analysis Criteria Before (Marker Method) After (Tag + Excel System) Improvement Search Time Average 5 minutes per part, sometimes longer when labels were faded or missing. Average 1–2 minutes per part, as tags are standardized and Excel file gives reference. 60–70% faster Information Accuracy Handwritten details often incomplete, inconsistent or faded over time. Tags contain chassis no, part no., date of replacement with Excel backup. Clear and accurate Labeling Reliability Ink fades, handwriting varies between technicians. Printed/written tags attached with cable ties, durable and consistent. Long-lasting, standardized Storage Organization Parts placed randomly, making retrieval confusing and time consuming. Excel log verifies part placement before storage, ensuring systematic organization. More structured storage Audit & Compliance High risk of noncompliance if part info was unreadable or missing during BMW audits. System allows traceability, verification, and faster audit response. Strong compliance Communication Miscommunication between technicians and warranty staff due to missing/unclear info. Excel log serves as a centralized reference, improving teamwork and accountability. Better coordination Cost & Tools Low cost but ineffective due to frequent mistakes and delays. Still low cost but more efficient and professional. Efficient with minimal cost Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 20 of 30 7.5 Unexpected Outcomes While the new tagging and Excel-based tracking system clearly made things better in the warranty storage room at Auto Bavaria Balakong, a few unexpected issues showed up once it was actually put into practice. One issue was that some technicians forgot to update the Excel file after attaching the tags. The parts were labeled correctly, but because the Excel log was not filled in right away, there were gaps in the record. This made it harder for the warranty staff to confirm whether part had already been stored. It showed that the system not only depends on the tools but also on consistent habits and reminders for the staff using it. Another issue came from the tags themselves. In a few cases, tags ended up damaged or even came loose after the parts had been in storage for a few days. Most of this happened because the cable ties were not tightened properly or the parts were handled roughly when stacked. While it did not happen often, it was enough to show that proper fastening and careful handling are important if the system is to work well. There were also some variations in retrieval time. Although the average dropped to just one or two minutes, sometimes it still took three or four minutes to find a part. This usually happens when the Excel log had not been updated immediately or when items were not placed in the right section of the storage area. Overall, these issues did not cancel out the improvements made by the new system. Instead, they highlighted the need for consistent discipline, simple training and regular monitoring so that the process becomes second nature for everyone involved. Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 21 of 30 8 DISCUSSION 8.1 Interpretation of Results The results of this project clearly show that introducing a tagging system together with an Excel-based tracking file is a big improvement compared to the old way of handling warranty-returned parts. The previous method, where technicians wrote details directly on the parts with markers, was inconsistent and unreliable. The writing often faded or became unclear, which made it difficult to identify and retrieve parts. As a result, the retrieval process was slow and created unnecessary delays in daily work. With the new system, every part is now tagged with clear and standardized information, including chassis number, part number and date of replacement. The use of cable ties keeps the tags securely attached, so the information remains visible and easy to read. This change has made the process more reliable and reduced the risk of incomplete or missing details. At the same time, the Excel log provides a centralized record that the warranty department can use to confirm whether parts are stored correctly, without having to depend only on physical checks (Sharma & Bhatia, 2018). The most noticeable improvement is in retrieval time. What used to take an average of about five minutes now only takes one to two minutes. This shows that the system is not only effective but also practical in supporting daily operations. It reduces interruptions during audits or inspections by BMW and ensures smoother workflows. The results also show that communication and coordination between technicians and the warranty department have improved. Because both the physical tags and the Excel log carry the same information, everyone has access to accurate and consistent records. This has helped strengthen compliance with BMW’s audit requirements and supported Auto Bavaria’s reputation for quality service. Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 22 of 30 Overall, the results highlight how a simple, low-cost and practical solution can bring major improvements to warranty part management. The system proves that efficiency, accountability and compliance can be achieved without the need for advanced technology, as long as the process is structured and followed consistently. 8.2 Implications The findings of this project bring out several important implications for how warranty-returned parts are managed at Auto Bavaria Balakong. First, the success of the tagging and Excel tracking system shows that meaningful improvements in efficiency can be achieved through simple and low-cost solutions. This suggests that similar manual approaches could also be applied in other areas of the workshop where clarity, accuracy and traceability are needed. For the warranty department, the new system provides a much more reliable way of managing returned parts, which directly supports compliance with BMW’s audit requirements. Being able to quickly locate and verify items reduces the risk of delays during inspections and lowers the chance of rejected claims. This not only strengthens Auto Bavaria’s credibility as an authorized service center but also helps maintain trust with the principal brand. The project also highlights the role of technician cooperation and discipline. The system’s effectiveness depends on technicians consistently attaching tags and updating the Excel file accurately. This implies that continuous training, regular monitoring and simple reminders will be important to ensure the process is followed properly over the long term. Another implication is the potential for scalability. While the current system is manual, it can serve as the groundwork for more advanced solutions, such as barcode Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 23 of 30 or QR code tracking, if resources allow in the future. This gives Auto Bavaria flexibility to expand and modernize its processes over time without losing the benefits already achieved. In short, the implications of this project extend beyond simply solving the problem of locating warranty-returned parts. It underlines the importance of structured recordkeeping, promotes accountability among technicians and gives Auto Bavaria a practical tool to meet current service standards while keeping the door open for future improvements. 8.3 Comparison with Existing Literature The results of this project are in line with existing literature on inventory and parts management, which consistently emphasizes the importance of accurate labeling and proper record-keeping in reducing retrieval times and minimizing inefficiencies. Previous studies on warehouse and inventory practices have identified unclear or inconsistent labeling as one of the major reasons items are misplaced or difficult to retrieve. The situation at Auto Bavaria reflected these findings, as the old markerbased system often produced faded or incomplete information that complicated the process of locating warranty-returned parts. Research also highlights the effectiveness of dual systems that combine physical identification with centralized digital records. Studies in the automotive sector show that even simple setups, such as using physical tags alongside spreadsheet-based records, can improve traceability and minimize the risk of loss. The outcomes of this project confirm that approach, as the use of printed tags together with an Excel file made part retrieval quicker and more reliable in the warranty storage room. Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 24 of 30 Another important theme in literature is the value of standardization in both labeling and data entry. Standardized processes reduce ambiguity, improve communication between staff and support compliance during audits. The proposed system directly aligns with this by introducing a uniform tag design and requiring consistent information entry into Excel, which helped reduce errors and improve accountability. One area where this project differs slightly from the literature is in the use of technology. While some studies recommend advanced solutions such as barcodes or RFID systems, this project demonstrates that significant improvements can still be achieved through low-cost manual methods. This highlights the importance of tailoring solutions to fit workplace conditions and available resources. In summary, the project’s findings support the broader body of knowledge in inventory and parts management, while also showing that simple manual systems can be a practical and effective solution in specific contexts, such as Auto Bavaria’s warranty department. 8.4 Limitations Although the proposed tagging and Excel-based tracking system has brought clear improvements to the management of warranty-returned parts, a few limitations remain that need to be considered. First, the system relies heavily on the discipline and cooperation of technicians. If a technician forgets to attach a tag correctly or fails to update the Excel log, the process becomes less effective. Human error, such as incomplete data entry or misplaced parts, can still occur and affect the overall reliability of the system. Design And Implementation of a Tracking System for Warranty Returned Parts in Auto Bavaria Balakong Storage Room Report Number: UNIMAP/FKTM/P1/221543713 WBL Company: AUTO BAVARIA BALAKONG Revision: C (Final Report) Date: 22/9/2025 Prepared by: MUHAMMAD HAZRI AMIRUL BIN ZAHARIN Verified by: HAMIZAN BIN BAYRI @ MD KHARI Checked by: Ts. Dr. Ing. MOHD NAZRI BIN OMAR TECHNICAL REPORT IFP Page 25 of 30 Second, the system is fully manual and does not include automation. While Excel provides a centralized record, it does not have advanced features that specialized inventory management systems offer, such as automated alerts or direct integration with other databases. This makes the solution practical in the short term, but it may limit scalability in the future unless further investments in technology are made. Third, the physical tags themselves have certain risks. Even though cable ties are used to keep them secure, tags may still be damaged or come loose due to rough handling or improper stacking in the storage area. This could lead to information gaps if not checked and monitored regularly. Finally, the scope of the system is limited to the warranty storage room at Auto Bavaria Balakong. It does not extend to tracking parts once they leave the storage room for return to BMW or for disposal. This means the system only addresses one stage of the warranty process and does not cover long-term tracking of parts. Despite these limitations, the system remains a simple, practical and costeffective solution for the current operational environment. With regular monitoring and the possibility of gradual upgrades, it can continue to deliver benefits and may even serve as a foundation for future improvements. 8.5 Recommendations Based on the findings and the limitations identified in this project, several recommendations can be made to further improve the tracking of warranty-returned parts at Auto Bavaria Balakong. First, regular training sessions should be arranged for technicians to ensure the tagging and Excel system is used consistently. Clear guidelines, short refreshers and