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Common traits of Successful RFID Projects in Manufacturing
- 1. S P O N S O R E D B Y
- 2. S P O N S O R E D B Y Common Traits of Successful RFID Projects In Manufacturing Carrie Angelico, Zebra Technologies Steven Walsh, Strategic Systems Janet Best, TE Connectivity
- 3. S P O N S O R E D B Y ZEBRA SPOTLIGHT
- 4. S P O N S O R E D B Y ENTERPRISE ASSET INTELLIGENCE
- 5. S P O N S O R E D B Y GLOBAL MARKET LEADERSHIP
- 6. S P O N S O R E D B Y ZEBRA’S UHF RFID PORTFOLIO • Fixed Readers • Handheld Readers • Printers • Antennas • Labels, Tags and Printer Supplies
- 7. S P O N S O R E D B Y Nearly half of all manufacturers are expected to implement passive RFID solutions within the next five years. → Review the current state of RFID in manufacturing → Discuss several use cases → Explore traits of successful RFID projects → Next steps → Q & A Agenda
- 8. S P O N S O R E D B Y Manufacturing’s Five-Year Outlook SOURCE: Zebra 2017 Manufacturing Vision Study
- 9. S P O N S O R E D B Y Saving money on labor, overhead, and supply costs isn’t enough. • Finding an imperfection slows down production, increases costs, and makes it significantly more difficult to identify the point-of-failure. • New processes and technology advancements are enabling companies to focus on quality. • Manufacturers are introducing quality checkpoints and automation at more stages in the process. Quality Isn’t an Option
- 10. S P O N S O R E D B Y Increasing Tracking Points Leads to Rising Quality SOURCE: Zebra 2017 Manufacturing Vision Study
- 11. S P O N S O R E D B Y The Shift from Pen & Paper SOURCE: Zebra 2017 Manufacturing Vision Study
- 12. S P O N S O R E D B Y Technologies Transforming the Factory Floor SOURCE: Zebra 2017 Manufacturing Vision Study
- 13. S P O N S O R E D B Y RFID Finds a Home on the Plant Floor SOURCE: Zebra 2017 Manufacturing Vision Study
- 14. S P O N S O R E D B Y Asset Management Is Critical for Success SOURCE: Zebra 2017 Manufacturing Vision Study
- 15. S P O N S O R E D B Y Use Case #1: Monitoring Cycle Times
- 16. S P O N S O R E D B Y The Problem Lack of visibility resulting in inability to mitigate component failure. • Unable to accurately capture component cycles • Unable to maximize use of components • Over manufacture of components
- 17. S P O N S O R E D B Y The Solution An RFID-based solution giving teams and managers visibility and actionable data. • Fixed portal UHF RFID (Zebra FX7500 reader and AN720 antenna) • On metal rugged UHF tags • StrategicRFID middleware • Cycle count application
- 18. S P O N S O R E D B Y Monitoring Cycle Times Using RFID
- 19. S P O N S O R E D B Y The Results Knowing the exact location of components controls costs and ensures productivity. • Identified max # cycles per component • Prevented catastrophic test failures • Eliminated over production of test components
- 20. S P O N S O R E D B Y Use Case #2: Inventory Visibility Major White Goods Manufacturer
- 21. S P O N S O R E D B Y The Problem Looking to improve the efficiency of maintaining inventory accuracy. • Individual bar code scans required • Product separation pre- scan required
- 22. S P O N S O R E D B Y The Solution • UHF RFID Portals at Dock Doors (Zebra FX7500 readers and AN480 antenna) • ‘Wrap Around’ Dual Dipole UHF RFID Tags • Trailer Tags • GPIO Switch • Configurable Tag Filtering • RFID Middleware • Integration to client system via API
- 23. S P O N S O R E D B Y Improving Accuracy Using RFID
- 24. S P O N S O R E D B Y The Results • Eliminated bar code reads for shipping / receiving • Improved shipping / receiving productivity • > 99% read rates • Positive loading confirmation • Positive receipt confirmation • GPIO switch and integration enabled improved ‘Turn Around’ times
- 25. S P O N S O R E D B Y Use Case #3: Managing Critical Assets
- 26. S P O N S O R E D B Y The Problem Needed a more efficient way to manage assets with financial value and operational value. • Tracking tooling (molds and dies) was inefficient with no data connections to system tool location, part configuration, ownership, and service history. • Tracking standard assets including lab equipment, presses, fork trucks, reeler’s, racks, overhead doors, air conditioning units, and lab equipment was prohibitively time consuming.
- 27. S P O N S O R E D B Y Inventory …. Where is it? Who checked it out? How did it get there? Where is it going?
- 28. S P O N S O R E D B Y The Solution A scalable, web-based fixed asset tracking solution with RFID capability. • Strategic Asset Tracking software • Zebra MC9190Z RFID scanners • RFID tags (Dependent on asset type) • Zebra barcode printer/encoding printer (Zebra ZD500r) • Identification labels • Miscellaneous cost (Personnel training/travel) Average cost per site: $30,000
- 29. S P O N S O R E D B Y The Results Deployed at forty sites around the world. Multiple additional sites are in process including facilities in Poland, Switzerland, and the United Kingdom. Twelve more being considered for future implementation. • Time reduction by 80% for asset activity count • Increased frequency of asset count for improved data accuracy • Resource reduction by 70% • Average labor savings of $6,480 per building and count • Identification of asset location internal and external • Instant Asset lookup in Web based application or SAP • Finance Showcase Project - Cycle count timeliness and accurate synchronizing count with SAP • Paperless operation
- 30. S P O N S O R E D B Y Return on Investment (ROI)
- 31. S P O N S O R E D B Y Future Plans • Expand the use of Asset Tracking (Molds and dies, calibration labs, tax and treasury) • Inventory Movement/Count/Verification (raw materials, work in process, reusable packaging, etc.) • RFID Flow to Warehousing (tracking mixed product on skids, product traceability, and handling efficiency) • Automatic Inventory Transactions (BOM and quality verification during production, supplier product tracking, and bin to bin transactions) • Connecting Engineering (Online part changeovers, part revision tracking, tooling prints, and tool service requests) • Plant Security (Vehicle and employee access, asset security)
- 32. S P O N S O R E D B Y Common Traits of Successful RFID Projects RFID is a proven technology that lends itself to wide variety of warehouse and factory applications. Half of all manufacturers expect to implement passive RFID solutions in the next five years. How can you ensure project success? → Choose the right technology → Quantify the return on investment (ROI) → Secure buy-in for RFID initiatives All of which lead to: streamlined assessment, likelihood of successful pilot, and implementation survivability
- 33. S P O N S O R E D B Y Next Steps Consider exploring RFID solutions to address complex data collection challenges. → Asset Management → Inventory Control → Personnel Tracking → Vehicle Tracking → Work-in-Process Contact an experienced RFID solutions provider to discuss your project.
- 34. S P O N S O R E D B Y
Editor's Notes
- Carrie is responsible for the evaluation and management of new strategic RFID business opportunities through partnerships and alliances across all vertical markets in North America. She guides business partners and end users with their development and adoption of UHF RFID technology. Steven Walsh is the Director of Professional Services at Strategic Systems & Technology Corporation. He has over 20 years’ experience successfully deploying RFID solutions for clients, both in the United States and Europe, and he continuously evaluates new and emerging products and technologies in the world of RFID and ‘Locationing’ technologies. Janet Best is a DES Engineering Analyst II at TE Connectivity. She has developed and provided innovation concepts for finance and manufacturing for more than ten years. She has introduced and deployed RFID technology in the manufacturing environment for tracking fixed assets, proof of concept for monitoring supermarket flow, and inventory through distribution centers. Janet has also been a driver for innovation in digital manufacturing such as visual production boards, work in process, capacity planning, and financial forecasting. Janet has been with TE Connectivity since 2004.
- Zebra Technologies recently commissioned a global study to analyze trends and challenges that impact manufacturing companies. The survey asked 1,100 executives from automotive, high tech, food, beverage, tobacco and pharmaceutical companies for their insights on adopting technology on the plant floor to increase their competitive position. Respondents identified the following transformational shifts in the next five years.
- In the recent past, manufacturers frequently looked for ways to save money on labor, overhead, and supply costs to effectively compete in the global marketplace. However, the rising number of product variants, the growing price of materials and rising customer expectations are shifting that model. Today, forward-thinking companies are embracing a quality-minded philosophy, and it is paving an alternate route to growth and profitability. New processes and technology advancements are enabling companies to focus on quality and reap the rewards that an automated and connected plant floor can deliver. According to the survey, manufacturers are introducing quality checkpoints and automation at more stages in the process. After all, checking the status of a product after it’s assembled and finding an imperfection not only slows down production and increases costs, but it also makes it significantly more difficult to identify the point-of-failure.
- Gaining quality in the manufacturing process means having multiple checkpoints and real-time monitoring along the production line. In a connected plant floor, every physical asset has a digital profile. Manufacturers use these profiles to track real-time location, material allocation and condition of assets. The data can also be used to improve the overall manufacturing process, eliminate bottlenecks, communicate with suppliers and ensure quality. Although only 24 percent of those surveyed currently have technology-driven tracking capabilities in place, it’s something manufacturers know they need. In five years, 63 percent of those surveyed plan to increase their tracking with more than 28 percent planning to adopt real-time monitoring.
- Today, 62 percent of those surveyed use pen and paper to track vital manufacturing steps and 50 percent are using spreadsheets or a computer on wheels. The use of pen and paper to track WIP is highly inefficient and makes the process susceptible to human error. While plant floor managers can use the data stored in spreadsheets to identify areas for improvement, it’s a time consuming, manual process. Providing plant floor employees with mobile handheld devices allows them to scan and collect WIP information in real-time, providing visibility to data that can help managers make faster decisions.
- Among those currently using relevant technologies, most are planning to expand their level of usage by 2022.
- Gaining quality in the manufacturing process means having multiple checkpoints and real-time monitoring along the production line. In a connected plant floor, every physical asset has a digital profile. Manufacturers use these profiles to track real-time location, material allocation and condition of assets. The data can also be used to improve the overall manufacturing process, eliminate bottlenecks, communicate with suppliers and ensure quality. Although only 24 percent of those surveyed currently have technology-driven tracking capabilities in place, it’s something manufacturers know they need. In five years, 63 percent of those surveyed plan to increase their tracking with more than 28 percent planning to adopt real-time monitoring.
- Real-Time Location Systems (RTLS) in the manufacturing environment enable a host of new benefits. Companies can use RLTS to collect critical data about assets including location, stage and condition. This provides actionable data that managers can use to make smarter decisions and improve production. The data collected by RTLS software can be sent directly from the factory floor to internal and external suppliers so that they can quickly respond to requests. This helps eliminate the need to store excess inventory. Over 50 percent of respondents plan to implement RTLS by 2022.
- FMC Technologies (now TechnipFMC) is a global leader in oil and gas projects, technologies, systems, and services.