Benefits of Error Proofing Through RFID

Manufacturers and suppliers have a clear and strong incentive to create error proofing systems that ensure products and components have been assembled and tested correctly before leaving the plant. To prevent delays in error detection, manufacturers need to comprehensively identify assemblies and components, verify activity throughout production and material handling processes. Manufacturers can leverage their ERP, quality control and manufacturing execution systems with real-time bar code and RFID input to close the loopholes in work-in-process tracking that cause production and sequencing errors.

Benefits of Error Proofing Through RFID

The following are the RFID applications that improve all operations between suppliers and manufacturers that prevent errors that commonly occur and improve visibility.

• Outbound Logistics: When manufacturers and their suppliers are collaborated they can improve operations and error-proof processes with RFID. Consider engines that are assembled at a supplier facility and shipped to the automotive OEM. The supplier can automate and error proof the outbound logistics as engines move from production to the trains or trucks for shipment. Each engine should be uniquely identified and loaded sequentially to support just-in-time production. The serial number and model is typically on the engine’s bar code label, but these symbols are not always convenient to read, especially in unattended material handling operations.

• Inbound Logistics: Manufacturers have to track the incoming shipments in the correct sequence order. Tagged racks can be read with forklift-mounted or dock-door readers as soon as they arrive at the facility and matched to an order or shipment notification in a database via a wireless LAN connection. Again, RFID data collection and wireless LAN connectivity can accurately record all movements and putaway locations. Real-time RFID tracking also improves visibility of inventory, materials and work-in process.

• In-plant Logistics: Racks that are conveyed with material handling systems can be identified with fixed-position RFID readers installed at strategic points throughout the facility. Error-proofing applications can prevent improper installations by automatically issuing alerts if products are out of sequence. By recording the unique serial number accurately and automatically of each component, manufacturers can quickly identify and find products that need to be reworked or recalled because of component problems.

• Additional Applications: An RFID infrastructure created for error proofing can support many additional beneficial operations. These include automated replenishment and kanban signaling, TREAD Act compliance, yard management, cross docking, picking and putaway, inventory management, asset tracking, automatic vehicle locating (AVL), returnable container identification and more.

This information gives you an idea about the error proofing with RFID applications and its benefits to improve various productivity operations.