Warehouse automation in detail

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  • 2. 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
  • 3. 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
  • 4. How RFID works? Radio command signal issued from reader Host Computer Modified signal containing data returned Reader 164B28F34 Antenna
  • 5. Warehouse Management Trend Over 90% of warehouses and distribution centers are still only partially automated or completely manual-based RFID solutions for improving back-end processes are available today and are proving their value every day in a variety of business environments.
  • 6. Warehouse Management Application Opportunities 1. 2. 3. 4. 5. 6. Receiving and Shipping Cross-docking Putaway and Cycle Counting Forward pick Replenishment Order Picking, Consolidation and Staging Physical Security Solution components 1. 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
  • 7. Diagram Assets Tracked Benefits Conveyor Scanning • • • • • • • • 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. Entry Way Scanning • Pallets • Containers • Shipment Units • • • • Automated delivery & shipment notification Prevent mis-shipments Automated bill of lading Improved cross dock / dock utilization Stretch Wrap Scanning • Cases of product on pallet • Every product on pallet • Each product or case level verification prior to shipping Overhead Scanning • Oversized Items • Pallets • Containers • • • • Hand Held Mobile • • • • • • Allows for exception processing • Rapid searching or inventorying • Rapid pallet or shipping unit build Manufactured Items Each product inside of case Cases Containers Inventory management Material handling Destination Inspection Aggregate/De-Aggregate Automated delivery notification Inventory management Staging operations Improved Conveyance usage
  • 8. Batch Wireless Fixed Station
  • 9. Wireless / Batch Inventory Management Where is it? What is it? What is inside the box? Material Handling Aggregate / De-aggregate What have I assembled or disassembled? How many do I have? Do I have enough? Material Handling By Destination Where is it going? Where has it been? Should it be here? Material Handling Inspecting / Maintaining Has this been repaired? Is this under warrantee? Has this been inspected? Is this complete? What is the asset’s status or state?
  • 10. Manufacturing / Warehouse Applications B D E F D A E E C G D A B F G
  • 11. Distribution / Logistics Applications B D E F G G C A D E D E F B
  • 12. Objective of Solution: To ensure the error free flow of goods between the procurement, warehouse and factory, using RFID technology. Procurement Distribution Production Warehouse Unit W.I.P. ERP
  • 13. Systematic approach to improve processes. Pursue towards Operational Excellence Thru Decrease in Total Production Cycle Time with Less Cost of Inventory, Increase in overall Productivity ,Increased capital equipment utilization with a high Job Satisfaction and Employee Retention.
  • 14. •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. Procurement
  • 15. •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. Warehouse 3PL
  • 16. 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. Distribution
  • 17. Business Drives Decisions Helps Information Provides Technology Business Needs Information Decisions Depend Upon Accurate Data
  • 18. Key Technologies Bar-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
  • 19. 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
  • 20. Various Stages Involve… Can you identify the pain areas?
  • 21. Complimentary Long Range and Short Range Passive RFID Container Tag associated to a… Pallet Tag associated to a… Carton Tag associated to … 8 UID Packaging Tags each with 1 associated UID item
  • 22. 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.
  • 23. 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.
  • 24. 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.
  • 25. 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
  • 26. Stacking: Boards on the Bay to guide and Identify the Location ID of the warehouse location. Standard Association as per the Protocols existing.
  • 27. Upload the Stacking / Picking Data / Stoke Reconciliation data to the Data base RFID Hand Held Reader Serial / Bluetooth / Wi-Fi / GPRS interface. Server/PC on Network
  • 28. 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
  • 29. 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.
  • 30. 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.
  • 31. 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.
  • 32. 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.
  • 33. 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.
  • 34. Comparison between Barcode and RFID Technology: 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. Typically in cases where Dust / Moisture is there RFID is more successful then Barcode because it doesn't need line of sight.
  • 35. 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.
  • 36. Phase 2 Implementation 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
  • 37. RFID Gate in Working with Digital display on the side for the workers
  • 39. Bill of Landing Material Tracking
  • 40. RFID Enabled Fork Lifts Images
  • 41. RFID Enabled Fork Lift with Display for online Status and job scheduled and any error display
  • 42. How RFID Enabled Fork lift works
  • 43. 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.
  • 44. Why RFID in Warehouse/Distribution? 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
  • 45. RFID Standards Many to choose from!
  • 46. 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
  • 47. Standards 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
  • 48. The RFID Supply Chain Vision Implement knowledge-enabled logistics through fully automated visibility and management of assets in support of the warfighter Manufacturers/ Suppliers Distribution Centers/Depots PASSIVE POEs/PODs Transportation/ Supply/ Theater Depots/TDCs LONG RANGE PASSIVE Using good information to reduce bad inventory. Customers PASSIVE
  • 49. Contact US MONTEAGE TECHNOLOGIES B-86, Sector – 60, Noida – 210310, INDIA
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