Transport items, shipping units, distribution containers or whatever label you want to give them play an important role in logistics and manufacturing. Referring to items such as:
- Pallets
- Plastic boxes or tote containers
- Roll cages
- Wheeled trolleys
- Crates..
..they’re used to transport stock within a factory or warehouse, between buildings and to end markets and customers. Their significance is sometimes taken for granted however isn’t lost on Finance and Logistics Directors. They form a significant capital outlay and cause operational disruption when shortages occur. So picture the significance of a busy warehouse loading crates onto pallets, ready to be shipped onto a regional distribution centre before being distributed to a customer. As the pallets are loaded onto a truck the inventory is updated, recording which units are heading out, what units they precisely are, the truck they will be loaded to and where they are heading. There is no manual recording of information, no forms and no delay finding out the information as it is in real time. So can RFID really be used in this way today and what are the 5 tips for better RFID use?
1. Determine what you want to track
In the example given stock, crates and pallets could be tracked however don’t be fooled into thinking one RFID tag will track everything. Technically all three items can and will be separated at any part of the journey, within the warehouse or outside of it. Plus tracking each piece has its own merits. To help order fulfillment stock and asset control. Be aware also that RFID models need to vary between open and closed loop operations i.e. where one or many parties are involved with distribution and supply of shipping units and stock.
2. Consider how the data will be collected
There are a number of variables involved with the data collection, even if we assume passive RFID tags on the shipping units. From the type of readers through to the number and type antenna deployed. These all have a bearing on the quality and quantity of information collected. For example if only passive RFID tags are used on pallets, how many and where should the labels be applied in order to ensure the best reads? How will this vary between pallet size and type i.e. plastic or wooden? Similarly antennas and passive tag readers can be split between more than one loading bay door. Whilst this reduces cost it can remove important data links between the RFID tag and the loading/unloading bay the tag passes through.
3. Decide what is best..barcode scanners/RFID portable readers or fixed readers
Barcode scanners can be used within an RFID environment. Juniper Innovations for example has software that connects barcode reads to RFID tag numbers. This has the potential for current operational barcode scanners to be used inconjunction with an RFID setup. Similarly it gives scope for EDA solutions such as the Motorola ES400to be used. Also RFID portable scanners can be used with Juniper Innovations’ software i.e. to read standard barcodes as well as scan RFID tags. So it is worth considering how and where in the operation different types of mobile data capture devices need to be deployed. Say as opposed to the fixed readers where in our example will be used at the loading dock door.
4. Look at how robust the tags need to be
RFID tag prices vary considerably from low pence per unit to over £4.00 each. This isn’t simply to do with sales pricing strategy or market conditions, rather whether the operations can use low cost printed tags or requires weather and water proof units that can survive cold environments or going through cleaning processes for example. The price of the tags obviously contributes considerably to the cost of any project, particularly when you also consider the variables discussed in (2) above.
5. Understand process robustness
If data is being linked in our example between stock, crates and pallets consider how this will be done systematically and within the operational processes. For example how do you link all 3 if only the pallets or the crates have RFID tags? How do you best manage pallets and crates that go out of circulation from one warehouse, only later then coming back into circulation as part of its cycle? What is the best way to manage returning stock?