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Rfid In Inventory


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The solution was implemented at one of the largest Stain steel profile manufacturer of the world

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Rfid In Inventory

  1. 1. Case Study RFID in Inventory – Steel Industry
  2. 2. Case Study- Viraj Profiles Ltd. • One of the largest Stainless Steel Profile manufacturer • USD 1Bn. Company and exporting to over 80 Countries • Multiple Manufacturing facilities • 8000+ employees • Shipping from multiple warehouses • Profiles are packed in bundles weighing approx. 0.5 tons • Bundles are placed at 150+ stacks across warehouse • Bundles are searched across stacks against orders
  3. 3. Operational Characteristics • Each bundle has unique code assigned and written by hand on it as per order received from the customer • Bundles are unloaded and placed randomly as per the space availability • Inventory of more than 5,000+ bundles at any time • Bundles are searched manually for against each order from the printed list carried by employees • Retrieval is done by over head cranes and are placed in the containers for shipping • Labour intensive search and retrieval process
  4. 4. Goals • Precise location of all the bundles in the warehouse • Faster retrieval of bundles • Zero mismatch while retrieval • Faster movement of inventory • Reduced labour
  5. 5. Challenges • Provide real time visibility of all the stock and locations in the warehouse • Precisely locate bundles across the warehouse • Avoid misshipment
  6. 6. Products Used • Psion Teklogix 7527C- G2 UHF Handheld Readers – 6 Nos. • UPM RFID Gen 2 wet inlays–20,000 Nos. • Vicinity RFID – VRIF Middleware for warehouse and inventory management
  7. 7. The Solution Step 1- Tagging locations • Zone Creation: Each location is assigned an RFID tag
  8. 8. Step 2 -Tagging Bundles • Every Bundle is tagged with an Gen 2 RFID tag • Tags are applied upon receiving the bundle at the warehouse • Each Tag has a serial no. printed on it for visual identification. • The unique bundle numbers are written on the RFID tags using handheld RFID readers
  9. 9. Step 3 – Inventory Reconciliation • Location tags are read and bundle tags for the location are mapped(read). • The process is carried out at the entire warehouse • The process is repeated at periodic intervals. • Manual inventory took 1 person 12 hours on paper • Using RFID it took 1 person 1 hour
  10. 10. Step 4 – Synchronization • Upon docking the handheld reader to the computer, the VRIF middleware synchronizes the Physical stock details to the Server • Any manual entry error during tagging is validated at this point.
  11. 11. Step 5- Generate packing list • Based on Orders received the packing list provided by their existing SAP system is now updated by the VRIF middleware with additional information like Location details and the bundle serial no. • Electronic Proof of Dispatch
  12. 12. Benefits • 99% inventory visibility • Increase in dispatch by 20% • High reduction in labour cost • No mis-shipment • ROI in less than 6 months
  13. 13. Contacts Vicinity RFID Solutions Pvt. Ltd. # 312, Building 2, Sector 3, Millennium Business Park, Mahape, Navi Mumbai – 400 710. INDIA Tel: +91 93200 68035/22 2778 0343 email.: Web: