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Automated ID RFID
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• Automated ID
• Bar Code
• Dot Peen UID
• 2D
• RFID
• Whats the big deal
• Types of Tags
• Myths vs Reality
• Applications
• Can RFID work for me?

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Automatic ID

• Barcode Considerations
• Application
• Product
• Location
• Document
• Compliance
• Symbology
• Material
• Adhesive
• Real Estate
• Read Distance

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2D Barcodes
QR Code PDF417 DataMatrix Maxi Code

Developer(country) Developer(country) DENSO(Japan) Symbol Technologies (USA) RVSI Acuity CiMatrix (USA) UPS (USA)
Type Type Matrix Stacked Bar Code Matrix Matrix
Data capacity Numeric 7,089 2,710 3,116 138
Data capacity Alphanumeric 4,296 1,850 2,355 93
Data capacity Binary 2,953 1,018 1,556
Data capacity Kanji 1,817 554 778
Main features Main features Large capacity, small printout sizeHigh speed scan Large capacity Small printout size High speed scan
Main usages Main usages All categories OA FA Logistics
Standardization Standardization AIM InternationalJISISO AIM InternationalISO AIM InternationalISO AIM InternationalISO
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Unique Identification(UID)

• UID is a Department of Defense program that will
  enable easy access to information about DoD
  possessions that will make acquisition, repair,
  and deployment of items faster and more
  efficient.
• The benefits of UID are numerous
• Item visibility regardless of platform or owner
  
• Lower item management costs
• Item data necessary for top-level logistics and
  engineering analysis
• Accurate sources for property and equipment
  valuation and accountability
• Improved access to historical data for use during
  systems design and throughout the life of an item
  
• Better item intelligence for warfighters for
  operational planning
• Reduced workforce burden through increased
  productivity and efficiency
• Improved inventory accuracy

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Dot Peen
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Whats the big deal?

• Wal-Mart, Target, Tesco, Metro, DOD
• Compliance Mandates
• Jeff Woods, Gartner Research VP
• In a well run consumer goods warehouse the
  operational improvements value is not there from
  RFID
• Trickle Down Effect
• Media Hype
• IBM Commercials
• Consultants
• Experimentation with RFID has been underway for
  some time
• Standards activity has been picked up by the UCC
  and EAN through EPC global
• RFID vendors are working to develop new products
  to meet the emerging standards
• Most top Consumer Goods suppliers are working to
  understand the intricacies and benefits of RFID
  to maximize their investments

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RFID Market situation
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RFID motivation two drivers
External Customer Compliance Mandates
Inbound Supply Chain and Internal Systems
Improvement

• Compliance motivation
• Retain my customer
• Cost conscious
• Look for internal return later
• Reacting now plan later

• Internal ROI motivation
• Identified business problems
• Cost savings objectives
• Efficiency gain expectations
• Planning vs reacting

Both motivations
RFID Solutions as an enabler
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RFID Tags
Label Inserts
Wooden Pallet with RFID Plastic Leader Boards
Plastic Leader Board Tags
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RFID Myths and Realities

• Myth 1 RFID is a talking bar code
• A bar code that broadcasts its serial number
• More data than most bar codes 128 bytes vs 1.1
  bytes (approx)
• Identify SKU plus unique serial number
• Read/write distributed database

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RFID Myths and Realities

• Myth 2 You can read every RFID tag every time
• Immutable laws of physics
• Tag placement, contents, orientation, nulls
• Good engineering and system design required
• Procedures will have to be altered

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RFID Myths and Realities

• Myth 3 You can take inventory with a push of a
  button
• Technology does not exist today and, if it did,
  it would be cost prohibitive
• Real time inventory by
• Tracking when it came in
• Where it was placed
• When it left
• System design, new procedures and employee
  training is required

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RFID Myths and Realities

• Myth 4 You can buy tags for 5
• You cant purchase 5 tags today
• Contingent upon billions of tags per year
• Simple, read-only serial number tags
• Requires experimental manufacturing and assembly
  processes, e.g. Fluidic Self Assembly and
  vibratory self assembly
• Gillette 500M order to Alien at 10
• Many applications require read/write
• Military for security
• Containers requiring updates
• WIP process control and work travelers
• Do not need 5 tags to derive an ROI

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RFID Myths and Realities

• Myth 5 RFID is easy to deploy
• Demonstrations are easy to set up
• Deployment in DC, warehouse, retail store or
  manufacturing facility can be challenging
• Analyze the environment
• Water, metal shelving, EMI emissions
• Similar to an ERP deployment

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Example RFID Shipping Label

• Practical Tag Memory G1 100 8-bit bytes
• G2 200 8-bit bytes - C1G2 TBD

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Mechanics
Benefits
Yard Management

• Incoming trucks logged-in
• Bill-of-Lading/Manifest matched to P.O.
• Temporary RFID tag attached to the trailer
• Scanning tag with handheld unit or as truck goes
  through a portal, writes manifest number to RFID
  tag
• If location tags are use, location is matched
  when trailer is dropped by driver
• If random location is used, RFID tag allows swift
  trailer location content identification

• Reduces lost shipments
• Increases delivery and unloading productivity
• All but eliminates cost of search and find
  activity
• Reduces excess inventory to cover lost loads
• Increases customer satisfaction by increasing
  speed and accuracy of availability and execution

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Mechanics
Receiving
Benefits

• As the pallet comes off the truck, a portal
  interrogator or hand-held device reads the pallet
  tag
• RFID allows immediate verification of all the
  contents of the load and visibility to the WMS or
  ERP system
• Forklift operators can be immediately directed
  for shipment disposition

• Trucks can be unloaded and recorded faster
  increasing productivity
• Full pallet or individual cases can be quickly
  routed for cross-docking or production
  replenishment
• Case-level tags eliminates the need to check each
  item
• Validation against ASN allows instant
  reconciliation and faster invoice settlement
• Human error is eliminated
• Inventory accuracy increases
• Inventory levels can be reduced

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Putaway Picking
Mechanics
Benefits

• Place RFID tag at each location
• Recommended for A and B level items
• RFID pallet tag or over-pack label on each load
• VMU interrogator automatically reads and writes
  tags
• Any scanning required by a WMS for location and
  pallet ID
• Hand-held unit can be used

• Workers can be guided to or identify product
  quantities and locations quickly
• If directed putaway and pick, VMU can alert
  incorrect action
• Item and location can be immediately matched,
  whether directed or random putaway process,
  eliminating
• Lost inventory
• Costly search and find
• Increase safety stocks
• Full-pallet picks validated without human action
  or error

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Mechanics
Benefits
Inventory Management

• RFID tag affixed to part, assembly or box
• RFID tag at each location
• Location and item conveyance (pallet, tote,
  container, box, etc.) matched at putaway
• Readers track rack locations, contents, moves and
  picks
• Portable readers used for cycle counting

• Location and item matching allows swift and
  accurate cycle counting
• Accurate inventory allows automatic item
  re-orders
• Search and identify activities eliminated
• Excess inventory reduction or elimination
• Optimized inventory allows space cost reduction

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Production Line Replenishment
Mechanics
Benefits

• RFID tag can contain exact pallet content,
  sequence and production line destination
• Forklift driver is directed to a load or picks up
  a random load and is directed to the proper work
  location
• Location tag at the work cell can be read by the
  VMU interrogator or hand-held unit to verify
  proper match
• ERP and WMS are updated
• RFID tagged containers, dunnage, totes, etc. can
  be used as a Kanban signal

• Ensures the right items are delivered to the
  right work station
• Decreases or eliminates production down time
• Reduces error correction time and costs
• Allows validation of Just-in-Sequence and In-line
  Vehicles Sequencing
• Improves workcell efficiency
• Increases on-time delivery

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Mechanics
Benefits
Just-in-Sequence Tracking

• Detailed product information through point of use
  makes receiving and line-replenishment swift and
  accurate
• Immediate sequence knowledge reduces mistakes and
  costs
• Correct matching of parts and assemblies to
  products increases speed to market and customer
  satisfaction
• Quick change over and reloading of materials to
  correct work location decreases delays and
  increases agility
• Optimizes warranty and recall reduction

• ERP or MES system produces listing of what was
  made in what order
• Listing is matched to ASN or other notification
  from the customer as to sequence and production
  line location
• Part/assembly/product detail can be written to
  the RFID tag
• Exact sequence of parts loading is written to
  container/dunnage RFID tag
• Items are loaded in sequence and container is
  shipped to customer

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Mechanics
Benefits
Product Tracking

• RFID tag affixed to part, assembly or box
• Tag can contain part number, location produced,
  production line, worker, date and other types of
  information
• Product genealogy can travel with the part
  through out its useful life or requirement of the
  process
• Portals, VMU or hand-held units can interrogate
  the RFID tag any where, any time to get a
  complete history of the item

• Allows product history to travel with item,
  eliminating wasted time
• Improves regulatory or maintenance reporting
• Minimize warranty risk
• Optimize service efficiency and customer
  satisfaction
• Increases efficiency if product recall is
  warranted
• Swift product ID
• Decreases ID costs

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Mechanics
Benefits
Sortation

• RFID tag carries data about cart contents, origin
  and destination
• Portal set up at various points along a high
  speed conveyor/sortation systems
• Portals read destination
• Computer tells sortation system where to route
  the carton for staging and delivery
• Information can be written to the tag and stored
  there for the receiving customer

• Ensures items in a shipment are in the proper
  sequence for customer
• Swifter and more accurate order staging
• Eliminates carton delivery to the wrong shipping
  lane
• Eliminates inaccurate order staging
• Decreases shipment delays and allows quick
  bill-of-lading and manifest validation
• Improves customer satisfaction

Faster and more accurate than tunnel barcode
readers since more specific information can
reside with the load to quickly direct its
destination
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Mechanics
Benefits
Shipping

• RFID tag carries data about pallet/package
  contents, origin and destination
• Customer order number and line items are verified
  and added to pallet or container tag at time of
  pick or order consolidation
• Computer tells delivery and inventory systems
  where to route the shipment and how
• Information can be written to the tag and stored
  there for the receiving customer

• Ensures items in a shipment are in the proper
  sequence for customer
• Swifter and more accurate order staging
• Eliminates shipment placement on the wrong truck
• Validates that trucks are loaded in the proper
  delivery sequence
• Decreases shipment delays and allows quick
  bill-of-lading and manifest validation
• Improves customer satisfaction

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Mechanics
Benefits
Plant Maintenance Field Service

• Plant or field equipment carries an RFID tag
• Tag can contain information such as last
  maintenance date, technician ID, parts upgraded,
  actions taken and next maintenance date
• Technicians read tag to verify equipment and
  location, perform maintenance or repair, and
  update RFID tag with newest data

• Ensures technician is at the proper location and
  equipment
• Allows quick reference of maintenance and/or
  specifications if out of contact with host system
• All technician activities and parts replacement
  can be immediately updated and remain with the
  equipment or location for next technician
• Eliminates wasted time and procedure errors

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Can RFID work for me?

• Line of sight not available
• Requires many reads at once
• Unattended scan necessary
• Security
• Counterfeit prevention
• Mandate

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Summary

• The Smart Warehouse
• Efficient in all operations
• Leverages technology
• Able to adjust to todays ever changing business
  environment