RFID in Manufacturing

RFID has proven its value in several facets of manufacturing including inventory control, supply chain management and work in progress (WIP).  RFID enables real time tracking of key items in customer workflow, which saves time and money.

 

In recent years, the virtues of ‘just in time’ and Kanban supply models have been hotly debated.  Implementing these systems relies on smaller lot sizes, which reduces inventories, which in turn, inherently increases the number of independent shipping and tracking “events”.  All of this information can add significant expense to and overwhelm classic barcode and Kanban “card” systems.  With its scalability and modularity, RFID can significantly reduce this expense with automated tracking of inventoried items.

RFID in Inventory Control

  • Increased inventory visibility
  • Real time location of necessary materials/supplies
  • Reduce Inventory stocks by 15% or more
  • Tooling/High-Value-Equipment Maintenance, Control & Tracking
  • Asset allocation / reallocation

RFID deployment results in higher inventory visibility by enabling real time location of needed materials.  Tighter control of inventory enables implementation of just in time production.  With greater knowledge of inventory levels and locations RFID will also reduce out of stock conditions.

RFID in Production Scheduling

  • Improved demand forecast
  • Real time knowledge of raw material and equipment location
  • Personnel tracking (resource allocation, safety)
  • Significant improvements in production scheduling
  • Disposal & tracking of hazardous by-products
  • Proactive maintenance

The increased level of inventory control enabled by RFID combined with improved demand forecast accuracy and  real time knowledge of raw material & equipment location will enable significant improvement in production scheduling.

RFID in Kanban

  • RFID aids Kanban protocols which use bins to track inventory levels & restocking schedules
  • RFID replaces traditional card systems
  • RFID is constantly and automatically obtaining & organizing information

RFID can greatly improve the efficiency of Kanban systems.  Bosch, Inc. has been successful in using RFID tags in its Kanban.  RFID enabled Bosch to move to smaller lot sizes and reduced inventory levels to enable ‘just in time’ production.  Bosch estimates annual savings of over $1 million.

RFID in Work In Progress (WIP)

  • RFID Provides real time location and status of Work in Progress units
  • Increases workflow efficiency
  • Tighter inventory control
  • Robust metal-capable tags needed in complex manufacturing environment

RFID can be used to tag work in progress enabling real time tracking of location and status of parts on an assembly line or workflow.  Each station can update the status of each step in real time enabling more efficient workflow and tighter inventory control.

Emerson & Cuming’s Solution

While not all assets employed and products created in a manufacturing setting are metallic, many are.  In a manufacturing setting, many of the assets employed and the products created are partially or entirely comprised of metal.   Emerson & Cuming’s new MetalTag Flex and MetalTag Heat were specifically designed with the manufacturing sector in mind. 

  • The “Accordion” surface of MetalTag Flex was not chosen haphazardly.  As the tag is bent, the front surface stretches while the back plane remains smooth, allowing the tag to adhere to a curved, cylindrical or otherwise irregular surface with a simple adhesive bond.  In circumstances where pressure sensitive adhesive (PSA)  is insufficient, the smooth rear surface lends itself to easy epoxy application. 
  • The performance of the tag is outstanding, with real-world handheld and static antenna read ranges of 2.5 – 5 meters on metal surfaces. 
  • The entire unit (innerworkings + package) is made of flexible & elastic material.  As such, energy imparted during a blunt force trauma is absorbed not only by the package, but the silicone within.  As a result, MetalTag Flex stands up to more physical abuse than most comparably sized hard plastic tags, which would be reduced to shards in similar circumstances.