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Warehouse Management
using RFID
“THE SOURCE FOR ACCURATE INFORMATION FOR ANY BUSINESS’S IDENTIFICATION NEEDS”
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What is RFID?
RFID(Radio Frequency Identification) is a technology that allows automatic
identification of objects, animals or people.
RFID is not just a better bar code
Capabilities
More data, greater accuracy, automated delivery
Line of sight not required
Reads 1000’s of items simultaneously
Benefits
Improved accuracy, visibility, operational efficiency and security
Opportunities to quantify processes and map improvements
Opportunities for exception based management
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RFID Components
Tag : It is a transponder that is made up of an integrated antenna and an electronic circuit. The information can be written and rewritten on a tag. The ID written on the tag is known as the EPC (Electronic Product Code).
Reader : An RFID reader is a device that is used to interrogate an RFID tag. The reader has an antenna that emits radio waves; the tag responds by sending back its data
Host Computer : It reads/writes data from/to the tags through the reader. It stores and evaluates obtained data and links the transceiver to applications.
Tag RFID Reader Host Computer
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How RFID works?
164B28F34
Host Computer
Reader
Antenna
Radio command signal issued from reader
Modified signal containing data returned
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TrendOver 90% of warehouses and
distribution centers are still only partially
automated or completely manual-based
Warehouse Management
RFID solutions for improving back-end processes are available today and are proving their value every day in a variety of business environments.
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Application Opportunities1. Receiving and Shipping
2. Cross-docking
3. Putaway and Cycle Counting
4. Forward pick Replenishment
5. Order Picking, Consolidation and Staging
6. Physical Security
Solution components1. Read/write RFID tags
2. CK30/IP4 and 24xx handheld computers
3. 700 color for supervisory use
4. CV60, 2455 and 2475 VMUs
5. Intermec or CISCO WLAN backbone
6. Planning, integration, implementation and education services
Warehouse Management
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BenefitsAssets Tracked
• Each product or case level verification prior to shipping
• Cases of product on pallet• Every product on pallet
• Verification of each product w/o opening case• Lot tracking of cases• Read/Write of data to case• Each product for reg., warranty of distrib.
• Manufactured Items• Each product inside of case• Cases• Containers
• Automated delivery & shipment notification• Prevent mis-shipments• Automated bill of lading• Improved cross dock / dock utilization
• Pallets• Containers• Shipment Units
• Automated delivery notification• Inventory management• Staging operations• Improved Conveyance usage
• Oversized Items• Pallets• Containers
Diagram
Stretch Wrap Scanning
Conveyor Scanning
Entry Way Scanning
Overhead Scanning
• Allows for exception processing• Rapid searching or inventorying• Rapid pallet or shipping unit build
• Inventory management• Material handling• Destination• Inspection• Aggregate/De-Aggregate
Hand Held Mobile
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Wireless Batch
Fixed Station
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Wireless / Batch
Inventory Management
Material Handling
By Destination
Material Handling
Inspecting / MaintainingMaterial Handling
Aggregate / De-aggregate
Where is it? What is it?
What is inside the box?
Where is it going? Where has it been?
Should it be here?
What have I assembled or disassembled?
How many do I have? Do I have enough?
Has this been repaired?
Is this under warrantee?
Has this been inspected?
Is this complete?
What is the asset’s status or state?
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B
A
D
B
E
E
D
G
E
C
F
F
A
G
D
Manufacturing / Warehouse Applications
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D
D
E
A
F
C
G
B
D
E
B
E
G
F
Distribution / Logistics Applications
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Warehouse
ERP
Procurement
Distribution
Production
Unit
W.I.P.
Objective of Solution:
To ensure the error free flow of goods
between the procurement, warehouse
and factory, using RFID technology.
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Systematic approach to improve processes.
Pursue towards Operational Excellence
Decrease in Total Production Cycle Time with LessCost of Inventory, Increase in overall Productivity,Increased capital equipment utilization with a highJob Satisfaction and Employee Retention.
Thru
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Procurement
•All items it’s own unique characteristics may be
due to some specific sales guidelines and Govt.
Regulations etc.
•Items packed and label containing crucial
information applied on the CBB.
•Each item will be uniquely identified.
•Item will be shipped to the warehouse location as
per the Dispatch Indent raised.
•Transportation details forwarded to the concern
Warehouse and Sales / Finance department.
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Warehouse
3PL
•Intimation for the receipt of the Item given
to the concern warehouse.
•Material reaches to the warehouse.
•Information entered on the register at the
gate.
•Material unloaded, verified with P.O.
Information.
•Materials stacked as per the predefined
procedure in the warehouse.
•GRN entry made and stock updated.
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Distribution
Supply of the right vehicles to the right
person / Dealer.
Control on the damage & Pilferages if any.
Fast and easy to use process for the
delivery.
Quick turn around time for the trailers.
Less storage time for the produced
vehicles in the premises.
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Technology
Information
Decisions
Provides
Helps
Business
Drives
Business Needs Information Decisions Depend Upon Accurate Data
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Key TechnologiesBar-code Printing & Scanning Technologies
Magnetic Strip,Biometrics & Proximity Technologies
Wireless LANs & Mobile Computing (RFDC )
Radio frequency Identification (RFID)
Embedded & Application Software Development
Wireless, IP Telephony & Internet Application
RFID Readers, Tags, Labels, PCBs
RFID enabled printing technologies
Memory cards
Secure memory cards
Crypto controller cards
GSM cards
Biometric cards
National id cards
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Tagging strategy
With many inlay types on the market for all types of packaging material, helps you decide which inlay works best and where it works best on your products to ensure it is read properly.
Installation & Continued On-Site Support
Through on-site services and support, We will help you maximize your RFID investment by ensuring that your solution is properly installed and achieving your targeted goals
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Various Stages Involve…
Can you identify the pain areas?
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Complimentary Long Range and Short Range Passive RFID
Pallet Tag
associated to a…
Carton Tag
associated to …
8 UID Packaging Tags
each with 1 associated
UID item
Container Tag
associated to a…
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1. WIP FG Stage and stock transfer to the FG Warehouse or Mother Warehouse
A. Automation of stock count and dispatch:
B. RFID Tag placement on the CBBs at defined location in the factory.
RFID Tag on CBBs
C. Read data on the RFID Tag using RFID Reader and maintain data base.
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2. Loading dock at
Material OUT from
Supplier
• CBBs will pass through a
RFID Dock door setup.
• All required validation will be
done automatically by
systems itself.
• Critical information stored at
loading stage in the
Application.
• This will generate the data
which will be imported in ERP.
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B. Warehouse Activities:
1. Receiving, GRN and Stacking:
GRN generation will be done automatically and data is verified
against ERP entries and during the stacking location id and CBBs
Batch are read and stored on data base.
2. Picking and Dispatch, Product Count:
Directed picking with location id listed on pick list and dispatch are
verified and loading sheet is generated automatically and product
count is done.
3. Stock Reconciliation:
Location tags hold the count of CBBs which are updated time to
time during the stacking or picking.
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Unloading/Receiving:
• Trolley carrying CBBs will
pass through a RFID dock
door setup.
• This will generate the data
for GRN and data is imported
in ERP to verify the factory
PGI data.
•Online data validation and
checks.
Stacking in
Warehouse
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Stacking:
Standard Association as per the Protocols existing.
Boards on the Bay to guide and Identify the Location ID of the warehouse location.
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Upload the Stacking / Picking Data / Stoke
Reconciliation data to the Data base
Serial / Bluetooth / Wi-Fi / GPRS interface.
RFID Hand Held Reader Server/PC on Network
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Picking:
Identify the stake to be loaded based on the Pick sheet generated by application S/W using Digital display at the loading gat or Hand Held Reader
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1. Receiving dock at
Warehouse
• CBBs will pass through a RFID
Dock door setup.
• Here systems will check the
desired pre requisite with the
actual process like FIFO,
Sequence of the Box, Grade of
the Material etc. online.
• This will generate the data &
validated against the Stock
request and same will be
imported in ERP.
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Loading/Dispatch at
Warehouse:
• Trolley carrying CBBs will
pass through a dock door
setup.
• Here systems will check the
desired pre requisite with the
actual process like FIFO,
Sequence of the Box, Grade
of the Material etc. online.
•This will generate the PGI
data for ERP.
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2. Dispatch from Warehouse
• CBBs will put on the conveyor in the sequence desired.
• Tags will be read and data will be validated against the recipe of
the final product.
• In case of any variance of the sequence of grade etc. error alarm
will be raised for corrective action.
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3. RFID Tags reuse
• Once the CBB is dispatched
CBB or tags which ever is
desired will be recollected and
send back to Procurement hub
for reuse.
• At the time of exit tags will be
read and will be declared free
again for reallocation with some
other CBB.
May be RFID Tags removed and
send back to factory for reuse.
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Stoke Reconciliation:
Solution provide total visibility in the Procurement & WMS
operation.
- Dispatch
- Receiving
- Staking (Directed and stack and CBBs association)
- Picking (FMFO on Batch Basis)
- WIP sequence / Blocked Material
virtual Stoke Reconciliation can done on the basis of random
selection of bays to verify the reliability of system.
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Comparison between Barcode and RFID Technology:
Typically in cases where Dust / Moisture is there RFID is more successful then Barcode
because it doesn't need line of sight.
RFID Barcode
Can read up to 300 feet and through materials. Requires a direct sight to the printed barcodes, a maximum
distance of 15 feet.
Up to several hundred RFID tags can be scanned in a single
second by one reader.
Barcodes are scanned once at a time.
RFID tags are typically more rugged, since the electronic
components are better protected in a plastic cover. RFID tags
can also be implanted within the product itself, guaranteeing
greater ruggedness and reusability.
The printed barcode must be exposed on the outside of the
product, where it is subject to greater wear and tear
Some (not all) RFID tags allow information to be modified. Once printed, a barcode cannot be modified.
RFID tags allow more sophisticated forms of data protection. Data on barcode could be encrypted; however, they provide no
protection from being copied.
NO Line of Sight required. Line of Sight required.
Typically unattained reading. Typically attained reading.
In few cases Reusable. Non Reusable.
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Cost Comparison between Barcode and RFID Technology:
Components Barcode RFID
Reader Fix Mount Reader(4 NO. each gate)Rs. 1,25,000/- unit
Fix UHF Reader (1 NO. each gate)Rs. 2,50,000/- each
Antenna Not Required UHF Antenna (4 NO. each gate)Rs. 25,000/- each
Tags Rs. 2 pre label Rs. 70 per label (25,000 Single purchase)
Reusability Not Possible 1000 times possible (Minimum)
Consumables Labels & Ribbons Labels or Tie
Backward or forward adaptation
Forward adaption Not Possible
Backward adaption possible & can be used parallel as backup measure.
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Warehouse Mapping
using RFID Tags:
Tag on every location in Warehouse used to identify and associate with CBBs to maintain FMFO and visibility in stock
Phase 2 Implementation
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RFID Gate in Working with Digital display on the side for the workers
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LOADING / UNLOADING AREA – RFID SCANNING GATE
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Bill of LandingMaterial Tracking
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RFID Enabled Fork Lifts Images
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RFID Enabled Fork Lift with Display for online
Status and job scheduled and any error display
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How RFID Enabled Fork lift works
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Why US for RFID SOLUTION?
• Only AIDC company focused for 100% working solution delivery with
worlds best Reader / RFID Labels / Software.
• We knows your business and how RFID can help you be more
successful
• Alliance with Major RFID companies / Software Companies like TAGEOS
/ STAR INTERNATIONAL / WIPRO / HCL etc.
• OUR RFID solutions provide more information to make existing
automated data capture systems even more productive
• Expertise in other AIDC technologies like Bar-coding, Biometrics,
Wireless etc.
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Most logical first step for most manufacturers:
Better Visibility into Location of Inventory throughout the distribution chain.
Reduced Warehouse Labour Costs Reduced Inventory Write offs (shrinkage, EOL, shelf life) Reduction in errors - Improved Accuracy Increased Throughput Lower Inventory Levels Improved Customer Satisfaction Customer Mandates
Why RFID in Warehouse/Distribution?
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RFID StandardsMany to choose from!
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RFID Standards
ISO 180006C - Freight containers — RF automatic identification
ISO 180006C - Supply chain applications of RFID - Freight containers
ISO 180006C - Supply chain applications of RFID - Returnable transport items
ISO 180006C - Supply chain applications of RFID - Transport units
ISO 180006C - Supply chain applications of RFID - Product packaging
ISO 180006C - Supply chain applications of RFID - Product tagging
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RFID for Item Management Air Interface (ISO 18000)
ISO/IEC 18000-1 - Generic parameters - Air interface
ISO/IEC 18000-2 - Parameters for air interface below 135 kHz
ISO/IEC 18000-3 - Parameters for air interface at 13.56 MHz
ISO/IEC 18000-4 - Parameters for air interface at 2.45 GHz
ISO/IEC 18000-6 - Parameters for air interface at 860-960 MHz
Standards
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The RFID Supply Chain Vision
Implement knowledge-enabled logistics through fully automated visibility and management of assets in support of the warfighter
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PASSIVE LONG RANGE PASSIVE PASSIVE
Using good information to reduce bad inventory.
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