Like other industries, manufacturing is changing due to automation and technology integration. Automation enables more real-time tracking and efficiency within production lines, inventory management, and logistics – all of which can be achieved using RFID technology.
This guide analyzes RFID in manufacturing including its core components, advantages, implementation practices, and industry forecasts.
What Is RFID In Manufacturing?
RFID stands for radio-frequency identification and operates by utilizing automated processes such as identifying and tracking a particular object, material, or equipment through the use of radio waves.
In manufacturing, RFID tags can be added to raw materials and semi-finished goods, tools, and even the final products to:
- Track and traced production lines.
- Minimize manual errors during inventory and quality checks.
- Streamline operations with automation.
RFID is used in precision demanding industries like automotive, electronics, pharmaceuticals, and food processing.
The Key Components of RFID Technology in Manufacturing
1. RFID Tags
RFID tags contain and send unique information that aids in the real-time identification and tracking of assets and can include the following:
- Active RFID tags: Best suited for tracking high value assets. These tags are battery-powered and transmit data without interruption.
- Passive RFID tags: Most suitable for inventory tracking. These tags draw power from the RFID reader and therefore have a limited range.
- Semi-passive RFID tags: These tags rely on a power source to power the chip but communicate with the reader.
Tags can be implanted in products, incorporated into tools, or inserted into the product’s packaging materials.
2. RFID Readers
RFID readers use radio waves to receive data saved in RFID tags, which can include:
- Fixed readers: These are placed at the entrance and exit doors, conveyor belts, and production lines.
- Handheld readers: These are used for inventory scans and audits and can be moved around.
In manufacturing plants, readers are placed at convenient locations for automating scans and eliminating manual barcode scans.
3. RFID System or Database
RFID systems hold and perform diverse functions with the captured and scanned data for example integrating with ERP and WMS systems to provide real-time information on the degree of production, stock available, and the state of logistics assistance.
How Exactly Does RFID Work in Manufacturing?
1. Security
RFID’s tracking abilities allow for plant access control by monitoring employee movements and preventing access to sensitive areas. Primary features include:
- ID badges with RFID capabilities for employees.
- Automated logs for compliance and security audits.
- Tracking visitors for safety management.
2. Inventory Control
RFID provides real-time inventory visibility for automated inventory tracking. Positive outcomes include:
- Alerts for stock levels help reduce material shortages or overstocking.
- Error-less tracking reduces human errors during warehouse management.
- Inventory scans are completed faster as manual barcode scanning is not required.
3. Quality Assurance
RFID improves quality assurance by aiding in confirming that every item has met regulatory standards before leaving the factory. It helps:
- Confirm defective parts are not used in assembly.
- Monitor expiration dates in food and pharmaceutical manufacturing.
- Ensure safety and industry regulation compliance.
4. Execution of Production
RFID tags attached to WIP (work-in-progress) materials optimize production workflows by:
- Monitoring the movement of parts and materials in the assembly line.
- Reducing idle time by ensuring timely delivery of materials.
- Monitoring processes in real-time to alleviate production bottlenecks.
5. Machine Performance
RFID can be fitted in manufacturing equipment to monitor its use, maintenance, and repair history which helps companies to:
- Decrease unexpected machine hibernation.
- Automatically set up preventive maintenance routines.
- Enhance Overall Equipment Effectiveness (OEE)
6. Logistics and Movement Monitoring
RFID makes supply chain management easier with the real-time tracking of shipments as well as guaranteed:
- Speedier order processing.
- Minimization of delivery mistakes.
- Greater efficiency in warehouse activities.
The movement of products across different manufacturers’ warehouses, distribution centers, and customer locations can be done without the manual scanning of barcodes.
What Are the Benefits of RFID in Manufacturing?
1. Operational Benefits:
- Increased productivity: Processes are automated, decreasing the need for manual activities.
- Improved accuracy: Human error during data collection is less likely.
- Faster decision-making: Analytics taken in real-time become more effective and response times improve.
2. General Benefits:
- Decreased labor costs: The number of manual inspections needed is lowered.
- Improved stock management: The stock level is monitored automatically.
- Improved customer satisfaction: Customer orders are processed rapidly and there is a reduction in mistakes.
Differences in RFID Technology and its Tags as Used in Manufacturing
Active vs. Passive RFID Systems:
Active RFID:
- Most appropriate for surveillance of valuable assets.
- Functions nearly one hundred meters away.
- Higher initial cost, but enables real-time tracking.
Passive RFID:
- Great for effective and efficient inventory control.
- More affordable since it has no battery.
- Needs RFID readers to power up and scan the tags.
Passive RFID Tracking System Advantages for Manufacturers
- Affordable for marking production at a larger scale.
- Requires little maintenance; no battery to change.
- If there is growth in factories or warehouses, it can easily adapt.
Controlling RFID Usage in Manufacturing
A Guide to Aid in the Beginning Stages of Implementing RFID Within Manufacturing
- Identify your needs: Determine the processes that can be operated once RFID is implemented.
- Picking the right type: Choose whether to have active, passive, or semi-passive systems.
- Choose the necessary RFID hardware and software: Spend on readers, antennas, as well as tracking software.
- Conduct a pilot program: Try out RFID in a limited area of the business before rolling it out completely.
- Train employees: Help everyone use RFID to its fullest potential.
- Monitor and Optimize: Analyze the data collected to continue improving the system.
Best Practices for RFID Implementation and Management
- Employ top-quality RFID tags as their failure could cost a lot.
- Ensure that RFID is used together with ERP & warehouse systems for better mobility tracking.
- Accurately scan tags by ensuring their placement is correct.
- Make changes to the system regularly with updates to RFID software to increase security.
Real-World Examples of RFID in Manufacturing
- Example 1: The RFID system of Toyota: Toyota has an inventory management that allows the company to follow components of a vehicle through various assembly lines improving accuracy along with productivity.
- Example 2: The Pharmaceutical Industry: RFID makes it possible to guarantee the authenticity of drugs by monitoring batches when going through the different stages of the supply chain.
- Example 3: Food Manufacturing: To ensure that food meets the needed safety requirements within the scope of RFID technology, the tags can monitor storage conditions.
The Future of RFID in Manufacturing
The next wave of RFID integration involves IoT, AI, and Blockchain. This will enable:
- Smart Factories: Manufacturing processes that are completely automated.
- AI-driven Analytics: Predictive analytics and maintenance along with demand forecasting.
- Supply chains: a transparent and untampered track system via Blockchain.
ASC Software: Partnering with you in RFID Tracking Solutions
Track your production or inventory in real time with ASC Software. From manufacturing to distribution, ASC Software’s RFID tracking solutions will cover all your needs.
Conclusion
ASHOW construction will from now on need precise and efficient movement tracking. No more guess working around cutting spots for now missed pieces. Easy graphical hints about missing parts will rejoice any construction manager alone with several RFID anchors.
ASC Software is changing the industry standard every step of the way. Now all businesses can optimize their costs and efficiency.
Lastly, every business owner looking to cut back spending and maximize every bit of profit will surely appreciate what automation and ASC Software are doing. By having a deeper insight into automation, ASC Software is bringing forth a new way of thinking.
