"Business Case for RFID in Industrial Applications"(down)


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"Business Case for RFID in Industrial Applications"(down)

  1. 1. Business Case for RFID in Industrial Applications Soroush Amidi Product Marketing Manager Honeywell
  2. 2. Agenda <ul><li>RFID Overview </li></ul><ul><ul><li>Passive RFID </li></ul></ul><ul><ul><li>Active RFID </li></ul></ul><ul><li>Business Case for RFID in Industrial Applications </li></ul><ul><ul><li>Safety </li></ul></ul><ul><ul><li>Security and Traceability </li></ul></ul><ul><ul><li>Workflow Optimization </li></ul></ul>
  3. 3. What is an RFID? <ul><li>RFID system are composed of RFID Tags or Transponders and RFID Readers or Transceivers. </li></ul><ul><li>Used to automatically identify and locate objects. </li></ul><ul><li>Most RFID tags contain at least two parts: </li></ul><ul><ul><li>An integrated circuit used for storing and processing information, modulating and demodulating (RF) signals and perhaps other specialized functions. </li></ul></ul><ul><ul><li>An antenna for receiving and transmitting the signal. </li></ul></ul>
  4. 4. RFID Tags <ul><li>Three types of RFID Tags: </li></ul><ul><li>Passive Tags </li></ul><ul><ul><li>No internal power supply. Incoming radio frequency signal provides enough power for the CMOS integrated circuit in the tag to power up and transmit a response. </li></ul></ul><ul><li>Active Tags </li></ul><ul><ul><li>Own internal power source used to power the integrated circuits and broadcast the signal to the reader. </li></ul></ul><ul><li>Semi-passive Tags </li></ul><ul><ul><li>Own power source but used just to power the microchip and not broadcast a signal. </li></ul></ul>
  5. 5. RFID Innovations <ul><li>Innovation around the design and manufacture of RFID tags is an ongoing process: </li></ul><ul><ul><li>Surface Acoustic Wave (SAW) technology. SAW technology involves the propagation of radio frequency acoustic waves on the surface of polished crystals. </li></ul></ul><ul><ul><li>Smart Active Label (SAL) technology offers enhanced range and accuracy attributes while being less vulnerable to liquid or metal. A SAL tag is essentially a semi-active smart label with its power source in the form of a thin, flexible battery. </li></ul></ul>
  6. 6. RFID vs. Barcode <ul><li>Economics of RFID more and more attractive as cost of tags drop, battery life increases and technology standardized. </li></ul><ul><li>Passive RFID tags </li></ul><ul><ul><li>Small and inexpensive (50 cents) </li></ul></ul><ul><ul><li>Tags must be placed in close proximity (less than a feet) to be read </li></ul></ul><ul><li>Active RFID tags </li></ul><ul><ul><li>Bigger than passive RFID and more expensive ($10-50) </li></ul></ul><ul><ul><li>Battery life varies depending of technology </li></ul></ul><ul><li>Barcode </li></ul><ul><ul><li>Much lower cost (1 cents) </li></ul></ul><ul><ul><li>Need to be scanned </li></ul></ul>
  7. 7. RFID Passive Tags <ul><li>LF – 125KHz and 134.2 KHz </li></ul><ul><ul><li>Range: Few inches to several fee </li></ul></ul><ul><ul><li>Access Control, Security, animal identification </li></ul></ul><ul><li>HF – 13.56 MHz </li></ul><ul><ul><li>Range: 5 to 1 m (2 to 3 ft) </li></ul></ul><ul><ul><li>Tracking for individual items, contact less payment </li></ul></ul><ul><li>UHF – 860 to 960 MHz </li></ul><ul><ul><li>Range: 3 to 5 m (10 to 15 ft) </li></ul></ul><ul><ul><li>EPC Global Class 1, V2 </li></ul></ul><ul><ul><li>Selected by Wal-Mart for Pallet/Container tracking </li></ul></ul><ul><li>Microwave – 2.45 GHz </li></ul><ul><ul><li>Range: up to 1 m (3 ft) </li></ul></ul><ul><ul><li>Lower Tag cost </li></ul></ul>
  8. 8. RFID and Location Gateway Location Server DCS or SCADA HMI
  9. 9. Accuracy vs. Range vs. Battery Life GPS AGPS 1 cm 1 m 10 m 100 m >10000 km 100 m 10 m 1 m UWB Active RFID Passive RFID 10 cm Wi-Fi Detection Accuracy Detection Range 1 year Battery Life <1 day >3 years
  10. 10. Agenda <ul><li>RFID Overview </li></ul><ul><li>Business Case for RFID in Industrial Applications </li></ul><ul><ul><li>Safety </li></ul></ul><ul><ul><li>Security and Traceability </li></ul></ul><ul><ul><li>Workflow Optimization </li></ul></ul>
  11. 11. Location and Identification <ul><li>RFID is used to: </li></ul><ul><li>Automatically identify assets within the reading range </li></ul><ul><ul><li>Ensures data is time stamped while person is close to asset (e.g. cannot be falsified &quot;pencil whipping&quot; as is the case with bar codes) </li></ul></ul><ul><ul><li>Ability to read and write to the tag should information change (e.g. new SAP #) </li></ul></ul><ul><ul><li>Long term more cost effective – they last for a decade or longer based on studies and hold up to harsh environments (e.g. painting, corrosion, sand blasting etc. ) </li></ul></ul><ul><ul><li>Ability to store significant amount of data (e.g. SAP #, OEM #, location #, Tag #, warranty/repair status etc.) </li></ul></ul><ul><li>Locate with various accuracy assets </li></ul>
  12. 12. <ul><li>Toll Roads </li></ul><ul><li>Cattle Industrial - Cattle identification </li></ul><ul><li>Shipping Industry – Pallet and container tracking </li></ul><ul><li>Pharmaceutical – Prevent counterfeit and errors </li></ul><ul><li>Automotive industry – Tracking engines and transmissions </li></ul><ul><li>Health care industry - Patient and equipment tracking </li></ul><ul><li>Retail industry - Inventory management systems as per Wal-Mart requirements </li></ul>RFID Applications in Non-Process Industry
  13. 13. Unlocking the Value of RFID-enabled Applications <ul><li>Operational Efficiency </li></ul><ul><li>Locate assets quickly on the field </li></ul><ul><li>Analyze asset utilization rate </li></ul><ul><li>Lay-down yard management </li></ul><ul><li>Maintenance and Inspections </li></ul><ul><li>Security </li></ul><ul><li>Access control of areas without physical barriers </li></ul><ul><li>Traceability </li></ul><ul><li>Safety </li></ul><ul><li>People/Asset Tracking </li></ul><ul><li>Process Interlocks </li></ul>
  14. 14. Safety Business Case <ul><li>Improve Safety and Emergency Response Time </li></ul><ul><li>Real-time Mustering </li></ul><ul><ul><li>Real-time tracking of personnel during industrial incident </li></ul></ul><ul><ul><li>Mustering reports generated within seconds </li></ul></ul><ul><ul><li>Accurate location of missing personnel </li></ul></ul><ul><ul><li>Comply with WAC 296-24-567 and OSHA 1910.38c </li></ul></ul><ul><li>Prevention </li></ul><ul><ul><li>Automatically stop or start a process based on location of equipment/assets </li></ul></ul><ul><ul><li>Automatically generate notifications when unauthorized personal or assets located in a restricted area. </li></ul></ul><ul><ul><li>Historical personnel/asset tracking for auditing purposes </li></ul></ul>
  15. 15. Safety Applications <ul><li>ROI </li></ul><ul><li>Defined by safety regulatory bodies for not meeting the requirements </li></ul><ul><li>Safety is #1 </li></ul><ul><li>Examples </li></ul><ul><li>Steel plant tracks trucks loading and unloading molten iron pot </li></ul><ul><li>Tracking 1,500 employees and contractors in a refinery during an emergency and obtain real-time head count at mustering areas and process units. </li></ul>
  16. 16. Board Operator View Integrated with Controls (Proc Ops or Interlock) Process Mode change interrupted due to people/asset in Unit Link to Security View Safety Applications
  17. 17. Security Applications <ul><li>Improved Security and Traceability </li></ul><ul><li>Monitor restricted areas without any physical barriers </li></ul><ul><li>Locating hazardous material within a plant </li></ul><ul><li>Reduce shrinkage </li></ul><ul><li>ROI </li></ul><ul><li>Measure number of units disappearing on a yearly basis </li></ul><ul><li>Measure time require to collect data for compliance purposes </li></ul><ul><li>Examples </li></ul><ul><li>US based chemical company tracks railway cars carrying hazardous materials by combining RFID and GPS </li></ul><ul><li>India based chemical company tracks cylinders throughout its global supply chain. This allows them to increase safety and security during the order fulfillment process. </li></ul>
  18. 18. Operational Efficiency <ul><li>Maintenance and Inspection Data </li></ul><ul><li>Ensures data is time stamped while person is close to asset (e.g. cannot be falsified &quot;pencil whipping&quot; as is the case with bar codes) </li></ul><ul><li>Equipment Management </li></ul><ul><li>Locate accurately expensive equipments used in the field </li></ul><ul><li>Lay-down yard management system (example: tracking assets during a Greenfield project) </li></ul>
  19. 19. Operational Efficiency <ul><li>ROI </li></ul><ul><li>Measure errors generated due to poor documentation </li></ul><ul><li>Measure time spent locating an asset during commissioning or construction phase </li></ul><ul><li>Measure equipment lost during a greenfield project </li></ul><ul><li>Examples </li></ul><ul><li>Scan tags associated to an asset during an inspection </li></ul><ul><li>Analyze the number of occurrences and time spent maintaining 80 batch reactors </li></ul>
  20. 20. Conclusion <ul><li>RFID is already being deployed today around the world in various industrial markets (Oil and Gas, Refining, Pulp & Paper, etc…) </li></ul><ul><li>Important to be aware of the different technologies available before selecting one </li></ul><ul><li>Identification and location data provided by the technology is used to improve safety, security, and operational effectiveness. </li></ul><ul><li>Business case required to provide a detailed look into improvements in key processes and related metrics to validate project ROI </li></ul>