© Tata Consultancy Services ltd. 28 June 2006 1

Putting RFID to work

T.S.Rangarajan (ts.rangarajan@tcs.com)Head, RFID SolutionsTata Consultancy Services Ltd. (http://www.tcs.com/rfid)

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Agenda

! What is RFID and how does it work?! RFID Tags and their classification! RFID readers! RFID Middleware! RFID applications and value chain! TCS in RFID! RFID case profiles from TCS! RFID and Print - Packaging

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! RFID identifies individual items" Aircraft assemblies" Aircraft sub assemblies" Aircraft components

! RFID tags consist of" Integrated chip" Integrated antenna" Varieties: Passive tags, active tags with (battery) power source, etc

! RFID readers can “read” many tags" Line of sight not required " Anti-collision prevents interference

! RFID readers may be" Handheld or stationary

! RFID equipment has its own allotted frequency band

What is RFID and how does it work?

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Antenna

Reader

• Uses radio waves or micro waves for quick & automatic identification • Detection/data transfer is contact-less and doesn’t need line of sight• Tags can store data and help maintain historical information

TagTag

Chip

Polyethylene Media

Copper coil antenna

Tag receives signal and gets charged

##

Antenna reads the data and sends to reader

$$ Reader sends data/info to computer for processing

%%

Computer sends event based data to be stored on tag

&&

Reader broadcasts signal through antenna

''

The Charged tag sends identifying response back to the reader

((RFID Middleware

EnterpriseApplications

RFID - a bird’s eye view

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125 kHz 13.56 MHz

UHF 902-928 MHz2.45 GHz

RFID tags

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Classification of RFID tags

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Low ( 125-134 kHz)

Read range – 2 meters Great penetration Slow data rate Costlier tag antennas Multiple tags cannot be read together

High Frequency (13.56 MHz)

Read range – 1 meter Good penetration Simultaneous read capability @ 50 tags Most progress on standard setting

UHF (868, 902-928 MHz)

Read range –10 meters. Fast data rate Simultaneous read capability @ 50 tags

2.45 GHz Read range – 1 meter Very fast data rate

• Spectrum use is often regulated by governments (13.56MHz designated for ISM applications in most countries)

• UHF frequencies (850 - 960 MHz) for RFID vary from country to country • Read range is greater with battery powered tags (active/semi passive)

RFID tags and their frequencies

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! Basic readers" Provide serial port interface" Host initiated Request-Response protocol" Basic commands includes reading a block, writing a block and locking

! Advanced readers" Provide serial and ethernet interface " TCP/IP stack included - provide Telnet and http interface " Provide command line and web interface " Advanced command set" Provide advanced digital inputs and outputs" Autonomous mode - response on user defined triggers" Heartbeat messages" Advanced outputs formats - text, XML

RFID readers

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Readability and range depend upon the design of readers and anteReadability and range depend upon the design of readers and antennaennae

RFID readers and antennae

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! RFID Data Characteristics" High Volume - some applications may have > 100,000 readers generating

terabytes of data" Fast rate - several reads / second" Multiple redundant reads of same tag data " Reader health monitoring and management

! RFID Middleware" Connects data from RFID readers to Enterprise applications " Device monitoring and management

! Middleware features" Device driver / control, diagnostics, remote maintenance, upgrades" Data aggregation " Data filtering and smoothing" Event monitoring" Connectivity

RFID middleware

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!Airlines baggage handling•Boarding pass•Package Tracking•Container Tracking•Yard Management•Toll collection•Fleet tracking •Rail car ID

Chips Inlays Antenna Middle ware

Systems Integration EAI

Analytics/ Process

RedesignTags Reader Reader

Network

Silicon companies – TI, Philips , Siemens, HitachiTag manufacturers –EMS, TI, Matrics, Alien

RFID Reader / Antenna makers – EMS, TI, Matrics, Alien, Hitachi

RFID Software providers – OAT, Sun, ORACLE, SAP, Globeranger, Matrics, ConnecTerra Savi

IT Solutions & Services providersTata Consultancy ServicesAccenture, IBM GS, CGEYWipro

!Supply chain management & distribution!Production management!Factory Automation!Maintenance / condition monitoring!Asset management

•Inventory management•Warehouse operation•Supply Chain Management•Interactive Kiosk•Self check out at POS•Electronic Article Surveillance

•Asset Tracking and Management• Contact less Payment solutions using mobile phones• Billing solutions• Various Value Added Services

Manufacturing Transportation Retail Telecom

•Asset Tracking•Patient tracking•Personnel tracking•Sterile Equipment management•Blood bags tracking•Anti counterfeiting of pharmaceutical products•Medicine dispensing

Healthcare

RFID applications and value chain

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Domain experience

Technology expertise

RFID Technology expertise

TCS RFID Solutions

Differentiation by synergy

• Pharmaceuticals & Healthcare • Transportation & Logistics • Retail & CPG• Manufacturing• Government• Utilities

RFID expertise & Assets• RFID Lab since 2001• RFID Center in Chicago• Presence in Oracle Sensorworld,

UK• Hardware & middleware expertise• Tools & assets

•Hospital Management system •Architecture

• ERP / SCM / WMS•Application development

•Application integration (EAI)•Business Intelligence & DWH

Strategic alliances• Oracle• Texas Instruments• Hitachi• Sun Microsystems• EMS

Member of

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Process consultingData and event utilization Strategy & Business case developEPC / GTIN consulting

Application DevelopmentCustom Modifications

Reader Interfaces, Reader Adapters,Filters and logger, Reader management RFID integration with EAI

Site Surveys Reader and Tag SelectionRF Engineering,Antenna placement & design ,

MIDDLEWARE

Business ProcessesBusiness Processes

Enterprise ApplicationsEnterprise Applications

Application / Integration Servers

Application / Integration Servers

Edge Processing LayerEdge Processing Layer

Hardware Interface Layer

Hardware Interface Layer

RFID HardwareRFID Hardware

TCSTCS’’ RFID StackRFID Stack

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• Established in 2001; approx. 20 researchers • Hardware: HF, UHF and MW from TI, EMS, Hitachi

and Alien• Middleware: Sun, Oracle and Auto-Id Center• Antenna footprint Analysis, Power Spectrum analysis,

Tag placement and readability tests

• Demonstrate industry specific RFID applications.• RFID physics related testing: Product evaluation and

benchmarking.• Integrate RFID hardware and middleware

RFID Center of Excellence

Kolkata

• Readers, antennas and tags: HF and UHF• Middleware from Sun, Oracle

Site Simulation Facility for Dock doors, smart shelf, conveyors

• Demonstration and piloting of solutions in numerous industry segments

• Access to leading RFID tech• Performance testing, analysis and benchmarking of

RFID hardware and middleware products.• Facilitate end-to-end integration testing

RFID Technology

Center, Chicago

Running real life scenarios for:• Asset Management Zone• Customer Experience Zone• Supply Chain Zone• Product Zone• Management Zone

• Ability to run pilots and test full scale implementation projects with our customers.

• Presentation and demonstration facility for TCS-Oracle RFID solutions

• To enable business mangers to see tangible evidence of the potential of RFID technologies to deliver business value

Sensor World, UK

DetailsObjectives

TCS RFID expertise centersTCS RFID expertise centers

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Enhancing airline MRO Operations! Client: ! Scope

" High value rotable parts at Heathrow warehouse" Integration with Enterprise MRO application

! Objectives" To improve performance and reduce cost" To improve the visibility of critical parts" To provide clear measurement of the impact of the pilot" To improve the service provided by the warehouse

! Benefits" Reduction of cost of labor associated with managing goods/business processes" Improve visibility into the incremental steps that are part of complex business

processes" Improve visibility into customer (Internal and External) demand" Better forecasting" Enhanced product visibility in the stores " Eliminating the possibility of misplacement of high value assets" Automatic recording of items’ entry and exit from the storage area" Reduction of manual errors in data recording & data entry

Case Study

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Engagement with a leading CRO! Scope:

" Specimen receipt management from investigator sites" Sample management

! Mode" RFID tagged Tubes

! Pain points addressed" Lack of end-to-end visibility for sponsor" Long trial times for sponsor" Long lead-times for patients

! Expected benefits: " Error Reduction at Investigator site " Reduction in shipment and stability related issues" Reduction in data management issues (automatic

scanning)" Chain of custody and effort reduction within central labs" Advanced Capacity planning/forecasting and allocation

! Increased stakeholder Satisfaction" Reduced loss of data points for clients" Reduced re-testing with patients (human aspect)

Unique ID linkedto back end systemfor automated Kitproduction line

Visit Scheduling

PackageReception

Sample Draw

Lab Testingand Results

Accessioning,Routing,

Aliquoting

During Transportation

CourierPickup

PackagingKit Samples

Visit Scheduling

PackageReception

Sample Draw

Lab Testingand Results

Accessioning,Routing,

Aliquoting

During Transportation

CourierPickup

PackagingKit Samples

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Authentication client

Authentication client

Authentication client

TI Reader

TI Reader

TI Reader

Product authentication serverWindows 2000 server

Oracle server

Oracle 10g server

RFID enabled product authentication scenario: a prototype

! Technology

" Microwave RFID tags" Handheld readers" Web based authentication application

! Features " Extremely small size of product" Tag is injection molded into product" Handheld RFID reader used for reads" Tags commissioned and ids are registered in database " Central authentication server " Thin authentication client " Web service based communication

! Benefits

" Impossible to duplicate product ids" Counterfeits can be easily detected" No other technology allows embedded ids" Flexible and scalable architecture

Metallicpart

Plastic“Nose”

Data cable

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RFID based inventory management for Kansas DOT! Client: Department of transportation, Kansas state, US of America! Scope: Identify how RFID can provide an optimum level of information for

" Capital Inventory tracking! These assets are dispersed over the entire State of Kansas and their value is $307,057,000+. ! The number of physical locations of the Capital Inventory is approximately 28 headquarters offices

in Topeka and 159 statewide field offices" Consumable Inventory tracking

! KDOT manages between $12 and $15 million in consumable inventory at any given time. ! There are 41 manned stock locations and approximately 420 unmanned locations statewide

" Materials Testing! Deliverables:

" Study Report! Impact on existing databases and applications! Impact on existing processes! Analysis of costs and benefits! Suggested roadmap

" Technology Recommendation Report! Includes hardware and software required for interfacing RFID system! Details of suitable RFID tags and readers! Middleware required! Network requirement

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RFID based inventory management

! Client: A leading medical equipment manufacturer.! Pain Areas

" Inaccurate inventory records " Data inconsistencies between the ERP and actual bin level

status" Every month, 2-3 days production is lost for cycle counting

! Solution" Manual bin cards replaced by re-writeable RFID tags " Reader applications developed to reduce errors" Data integration was done with the ERP

! Benefits" Instant visibility of stock due to real-time updation" Elimination of error due to manual entry" Automatic checking of parts being picked" Cycle counting eliminated

! Technology" Passive tags HF tags on Warehouse bins" Handheld reader" Integration with Oracle Apps

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! Client" Indian defense division

! Scope" Document and file tracking

! Features" Handheld RFID reader integrated to PDA" Automated document inventory and tracking application" Synchronized with desktop document management

application " Document issue history available in document itself

! Benefits" Improved document inventory visibility" Reduction in misplaced documents" Reduced effort in tracking classified documents

! Technology" High Frequency RFID tags from TI" Handheld RFID reader

RFID based document tracking

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! Client" A leading auto auction house, US

! Pain Areas" Difficulty in locating individual cars in an area spread across 80 acres" Manual identification and tracking process extremely time consuming, error prone" Mandatory verification of buyer ID and vehicle ID at exit cumbersome

! Solution" RFID tags fitted to each vehicle" Identify and track vehicles at entry, parking lot, detail shop, run lines and exit" Integration with existing auctioning application" Metrics collection on vehicle sales and cycle times" Status reports and dashboard " Verification of buyer id and vehicle Id at exit

! Technology" Active tags on vehicles to be identified and tracked" Fixed and Handheld readers

! Benefits" Ensure complete up to date inventory" Replace labor intensive bar code system" Automatic billing" Enhanced security" Market intelligence

RFID based car tracking

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! Client: " A premier Electrical equipment manufacturer

! Scope: " Asset and equipment tracking at power plants

! Technology" Passive tags on equipment /asset to be tracked and maintained" Active tags in case assets may move over a wide area" Gate and Handheld readers

! Features" Identify location of equipment / assets" Asset / Equipment identifies itself" Data storage capabilities - update equipment history on tag" Handheld displays equipment details to field worker" Automatic upload of field data to servers after field work is completed " Integration with Asset Management application ( Oracle database)

! Benefits" Accurate identification" Superior performance in harsh environment" Local data storage and availability without need of data networks" Reduced workload and increase in efficiency

RFID based asset management

RFID Reader

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! RFID based management of quality tests on tobacco samples in a cigarette factory

! Objectives" Reduce time required for testing lab samples" Reduction of manual effort in data recording & data

entry" Reduce data entry errors

! Features " Identification and Tracking of tobacco samples" Automatic data capture at sample collection site and

laboratory" RFID tags metallic tobacco containers" Specially designed tags to withstand high

temperature cycles" Integration of RFID reader with weigh scales" Automated capture of tag id and weight from

weighing scale" Data logging to QMS database" Reports and query support

! Technology" Passive HF Tags ( TI)" HF Fixed Reader ( Custom designed)" Handheld Readers ( Psion Teklogix)" MySQL database" .Net application

RFID Based Tobacco Quality Management

RFID based quality system for tobacco

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Salient Features of Lorry tracking System Application! Zonal tracking of lorries inside the facility! Application developed on MS DOTNET platform! Integrated with photo-pass system! Integration with SAP ERP! Accessible through Mobile platformScope of work ! Hardware:

" Procurement from NEDAP, Netherlands" Installation at site" Testing and system configuration

! Application development: " Requirements gathering and SRS preparation" Software development

! Integration: " Interfacing various hardware components like RFID, photo

pass camera, etc, " Providing an interface for integration with SAP systems at

multiple instances! Support:

" Training and implementation support

Benefits! Higher customer satisfaction: as real-time status of the location of the

lorry will be communicated to the owner of the lorry as well as the consignee.

! Better queue management: as the information of the movement of traffic is available at the entry point.

! Responsiveness: of the system to manage any changes in the filling order

! Reduction in administrative effort! Arresting discrepancies in scheduled orders

RFID based lorry tracking inside a refinery

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! Body shell tracking in an automobile paint shop! Technology

" Low Frequency ( 134 KHz) RFID tags from TI" High temperature tags capable of withstanding 350

deg C" Fixed RFID reader

! Features " RFID tags used for identifying and tracking body

parts in paint shop" Fixed RFID readers placed at 7 locations in

paint shop" Tags placed on skids that carry the body shell" Readers integrated with plant automation

system ( PLC) " Body Serial number, colour code, model

description code etc. is associated with RFID tag and used at different locations

! Benefits" Automated identification of body shell" Decentralized control of manufacturing

based on RFID tag

RFID based body shell tracking in automobile paint shop

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RFID and Print - Packaging

! RFID label printing! RFID tag printing? (Swedish companies - Thin film

electronics, Sensible Solutions, Cypak)! RFID tags are currently stuck on packaging only – case ,

pallet level and even item level)! RFID printers – Printronix, Zebra, Avery Dennison, Sato

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