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Traceability in Industrial ManufacturingWolfgang KratzenbergRFID Marketing Manager, [email protected]
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TraceabilityCapitalizing on Industrial ID
Driving Your GoalsA Traceability program improves the following areas…
– Comply with regulatory and quality standards– Proactively manage product recalls with
near-real-time corrective action– Improve customer safety, customer
satisfaction, and profit margin– Manage product quality and reduce
the cost of nonconformance
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Areas benefiting from Traceability…
Receiving Material Flow (Kanban)
PlasticsMachining
Forming
yAutomated Assembly
Shipping & Sequencing
Tool Room
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TraceabilityCapitalizing on Industrial ID
Plant Functions requiring Traceability:• Asset Tracking – plant-based assets• Electronic Kanban – plant-based material flow• Intra Logistic – material flow between plants• Production control (WIP) – assembly processes
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TraceabilityCapitalizing on Industrial ID
Key ROI Elements – Asset Tracking• Reduce asset losses• Reduce asset's non-
productive time
• Increase asset utilization• Ensure correct asset is used• Increase overall asset productivity
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TraceabilityCapitalizing on Industrial ID
Commonly Tracked Assets:
Totes/containers: Contents, location, usage, and part matching.Hand tools: Calibration data, location, use level, and part matching.AGVs (Automated Guided Vehicles): Location, flow control, usage, and maintenance.
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TraceabilityCapitalizing on Industrial ID
Key ROI Elements – Electronic Kanban• Reduce levels of in-process inventory• Maintain tight control of in-process inventory levels• Implement Just-in-Time inventory flow with outside vendors
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TraceabilityCapitalizing on Industrial ID
Kanban Systems – Plant based material flow
• System to provide just-in-time (JIT) delivery• Key points: Manage workflow & limit WIP
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TraceabilityCapitalizing on Industrial ID
Kanban Material FlowHow it looks in the manufacturing plant
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TraceabilityCapitalizing on Industrial ID
Key ROI Elements –Intra Logistics
• Maintain tight flow control with multiple sub suppliers
• Reduce time and potential errors when receiving components
• Maintain high level of visibility and traceability from sub suppliers to finished products
• Maintain regulatory compliance
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TraceabilityCapitalizing on Industrial ID
Primary RFID system is UHF• Long range: measured in feet• Reads multiple tags at once
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TraceabilityCapitalizing on Industrial ID
Key ROI Elements –Production Control• Enable flexible manufacturing• Track the rework process• Effectively handle product recalls• Maintain regulatory compliance• Manage Work-in-Process (WIP)
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TraceabilityCapitalizing on Industrial ID
What is being tracked…– Build Data: What are we trying to build (for flexible MFG)– Process Data: How well did we build it (Error Proofing)– Lineage Data: Where did all the parts come from
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TraceabilityCapitalizing on Industrial ID
Build DataKey component in a Flexible Manufacturing Environment
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TraceabilityCapitalizing on Industrial ID
Process DataDrives rework and Statistical Process Control (SPC)
Rework Lane
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TraceabilityCapitalizing on Industrial ID
Lineage ConceptData from multiple locations into one location
Critical for:• Recall information• Liability claims• Regulatory
compliance
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TraceabilityCapitalizing on Industrial ID
Communication Options Handheld• Offers great flexibility• Care must be taken that the user
connects with the appropriate tag
Fixed Mount• Preferred method• Most economical • Aligns intended data with correct tag
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TraceabilityCapitalizing on Industrial ID
Balluff Product Architecture
Modular Expandable Architecture with Dedicated RFID
Dedicated RFID
Read-Only RFID
Modular Expandable Architecture
Long-range UHF
Vision Sensor Barcode
Mobile Handheld
Read/Write
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TraceabilityCapitalizing on Industrial ID
Other Sources of information… • Traceability in Manufacturing
Brochure• Dedicated Web Page
www.balluff.us/traceability
• Whitepaper
• Booth 700 at RFID Journal Live 2013!
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Wolfgang KratzenbergRFID Marketing Manager, [email protected]