zebra technologies: utilization of rfid for in-plant visibility and optimization

THE SMART CONNECTED ENTERPRISE

Mark Wheeler

Zebra Technologies

RSTech ED Forum

6/2/2015

Leveraging RFID for Plant Visibility

May 2015

Agenda

• Zebra Technologies

• Internet of Things

• Visibility

• Active RFID / RTLS

• Passive RFID

• Use Cases

3

Channel partners in more than 100 countries

Customers include more than 95 percent of all Fortune 500 companies

Zebra

Facts

122+ offices

across 81 countries

$4.56 billion

market cap

4,200+ US &

international patents issued and pending

7,000 employees worldwide

KEY TECHNOLOGY OFFERINGS

4

Cloud-based

Device Management

Data Capture

RFID

Wireless LAN

Location and

Motion

Sensing

Card

Printing

Mobile

Computing

Barcode

Printing

25%

OF SURVEYED FIRMS IN 2014 ALREADY HAD

A IoT SOLUTION IN PLACE COMPARED WITH

ONLY %15 OF SURVEYED FIRMS IN 2012.

>80%

OF INDUSTRIES, COMPANIES AND TEAMS ARE READY TO MAKE CHANGES REQUIRED FOR IoT IMPLEMENTATION.

THE RIGHT TECHNOLOGY

SOLUTIONS ARE CRITICAL

- Forrester , “Internet-Of-Things Solution

Deployment Gains Momentum Among Firms

Globally,” 2015

IoT: THE INTERNET OF THINGS WHAT DOES IT MEAN TO YOUR BUSINESS?

Smart interconnected devices that businesses

use to get more visibility into the identification,

location, and condition of products, assets,

transactions, or people to drive more effective

and timely business decisions or to improve

customer interactions.


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

1 Completely

disagree

2 3 Agree 4 5 Completely

agree

Don't know NA

% R

esp

on

de

nts

Impact of IoT on Enterprise & Industry

The adoption of Internet of

Things solutions will be the

most strategic technology

initiative my organization

will have taken on in a

decade.

The realization of Internet

of Things solutions will be

the most important

technological initiative the

business world has seen in

a decade.


40% 45% 50% 55% 60% 65% 70% 75% 80%

Tracked transactions

Status of tracked personnel

Autonomous identification

Condition of monitored environment

Data driven actionable insight

Location of tracked personnel

Condition of tracked objects

Contents of tracked containers

Location of tracked containers

Location of tracked objects

% Respondents

Functionality IoT Expected to Deliver


0%

10%

20%

30%

40%

50%

60%

% R

esp

on

de

nts

Most Important & Challenging IoT Enabling Technologies

Very

Important

Very

Significant

Challenge

IoT: THE INTERNET OF THINGS HOW DOES THIS APPLY TO YOUR BUSINESS?

IoT BENEFITS:

REAL-TIME ACCESS TO THE CONDITION,

LOCATION AND STATUS OF ASSETS &

MATERIALS

SUPPLY CHAIN OPTIMIZATION AND

RESPONSIVENESS

CUSTOMER SERVICE

IoT CHALLENGES:

MANAGING COMPLEXITY

MAINTAINNG SECURITY

ENABLING APPLICATIONS

BY CONNECTING YOUR MOBILE ASSETS THROUGHOUT THE EXTENDED

ENTERPRISE, YOU CAN OPERATE MORE EFFECTIVELY.

Zatar

An IoT Platform

IoT: THE INTERNET OF THINGS ARE YOU TRANSFORMING YOUR OPERATION?

RFID: RADIO-FREQUENCY IDENTIFICATION.

WHAT’S NEW?

RFID: PASSIVE INVENTORY TAGGING SUPPLY CHAIN VISIBILITY

PICK / PACK

SHIP VALIDATION

RECEIPT

PACK

SHIP VERIFICATION

RECEIPT

INVENTORY

MARKDOWN

POS

EXIT DOORS

RETURNS

SUPPLY CHAIN

RFID ≈ 100% SCAN

SERVICE BUREAU /

IN PLANT PRINTING

SYSTEMS

BUSINESS TAGS ASSETS AT AN

ITEM LEVEL AT

ALL FACILITIES

111 GIGABYTES RESULTING DATA

31 TERABYTES

OVER

OF TRACKING DATA EVERY DAY

NUMBER OF TAGGED ITEMS REACHES OVER

10 BILLION

EVERY TAG READS SOMEWHERE ALONG THE SUPPLY CHAIN ONCE EVERY

5MINUTES

PER TAG

12 BYTES

RFID: WHERE WE ARE TODAY…

RFID IN ACTION TDM: A REAL WORLD EXAMPLE PROBLEM:

TROY DESIGN MANUFACTURING (TDM) – A SUBSIDIARY OF FORD

MOTOR COMPANY, NEEDED TO AUTOMATE THEIR WORK IN PROGRESS

(WIP) TO BETTER TRACK >150 VEHICLE CONVERSIONS.

SOLUTION:

• ZEBRA FIXED READERS AND ANTENNAS WERE INTEGREATED WITH

LOWRY’S Work-In-Process (WIP) SOFTWARE TO PROVIDE DETAILED WORK

INSTRUCTIONS, A BOM, AND A UNIQUE TRACKING ID FOR EACH VEHICLE.

• RFID AUTOMATED THE WORKFLOW PROCESS WHICH SHAVED 1.5

MINUTES OFF THE TIME SPENT BY EACH VEHICLE GOING THROUGH THE

10 STATIONS.

• RFID USE LEAD TO MORE ACCURATE DATA COLLECTION,REAL-TIME

VISIBILITY, AND CONSISTENCY, SETTING A HIGHER STANDARD FOR

FACILITY AND EFFIENECY POTENTIAL.

RTLS: REAL TIME LOCATING SOLUTIONS HOW DOES IT WORK?

RTLS TRACKS PEOPLE, MATERIALS AND ASSETS IN REAL TIME BY

UTILIZING ACTIVE ULTRA WIDEBAND (UWB) RFID TECHNOLOGY. THE

CAPABILITIES IT PROVIDES ARE ENDLESS.

RTLS: REAL TIME LOCATION SOLUTIONS WHAT DOES IT MEAN TO YOUR BUSINESS?

RTLS BENEFITS:

OPTIMIZATION OF TASK ASSIGNMENT BASED ON

LOCATION

VALIDATION TASK IS COMPLETED

REDUCED SEARCH TIME FOR STAGED MATERIALS

& EQUIPMENT

IMPROVED LIFT TRUCK OPTIMIZATION

REALTIME

REPORTING & ANALYSIS

VISIBILITY AND CONTROL OF CONTAINERS &

YARDS

ACTIVE UWB SYSTEMS CAN PROVIDE HIGHLY ACCURATE REAL-TIME 4 WALLS

LOCATION VISIBILITY.

RTLS CHALLENGES:

INTEGRATING CAPBILITIES INTO EXISTING EXECUTION AND PLANNING SYSTEMS

NEW THINKING TO LEVERAGE RTLS TO REALIZE ROI

Ultra

Wideband ISO 24730 Passive

RFID

1D or 2D

Barcode

ZEBRA VISIBILITY PLATFORM

GPS

Location and

identification

infrastructure

Data aggregation

& business rules

engine

Application and

integration

framework

Zebra and 3rd

party business

applications

Zebra Application Framework (Data and event processing, persistence, visualization, notifications, APIs, SDK’s)

Partner Apps Zebra Software

Solutions Motion Works, Material Flow,

Yard Management, Vehicle

Tracking

Asset Visibility

integration (Supply Chain visibility, Asset

location and status) Partner

Integration

SAP (Asset Manager)

IBM Maximo (Asset Manager)

Zebra Location Platform (data interfaces and connectors, sensor APIs to any devices)

LOCATION

IDENTIFICATION

PLATFORM

RANGE & ACCURACY OF

COMPARATIVE TECHNOLOGIES A

ccu

racy

1 10,000

System Range (Feet)

10 100 1,000

GPS

Passive

RFID

Active RFID

DART - Ultra Wide Band

Active RFID

WHERENET RTLS

ISO 24730

ASSET VISIBILITY

Tagged Assets will appear as colored dots/squares on

the map, you can see the details of the asset by double

clicking on the dot. Tagged Assets will appear as colored dots/squares on

the map, you can see the details of the asset by double

clicking on the dot.

GATE AND YARD

VISIBILITY/ACCOUNTABILITY

Key Challenges

• Accurate Check-in/Check-out

• Throughput

• Resource Utilization

• Yard Inventories

• Part/Assembly Visibility

Solution

• Enterprise Software

• WhereSoft Yard

• Visibility Suite (VSS)

• Technology

• Active RFID

• Passive RFID

• Barcode

Solution Features

• Automatic Gate Check-in

• Automated Switching

• Rules Engine for Automated

moves

• Real Time yard inventory

• Yard Activity reports for

continuous improvement

CASE STUDY MAJOR OEM:

INBOUND YARD

BEFORE

WhereSoft Yard

AFTER

WhereSoft Yard

Manual Gate Check In Increased throughput at the gate

Manual Switching Reduced trailers onsite

Loss of visibility to stored inventory Real time visibility to trailers and contents

Underutilized labor force Labor productivity up 20%

Underutilized equipment Increase moves per switch truck

Excess waste (movement) Elimination of manual yard checks

Frequent line-stoppages Visibility to inventory after it enters yard

PLANT FLOOR

Key Challenges

• Location of Key assets

• Throughput

• Resource Utilization

• In Process Inventory

• In process / Finished goods visibility

• Rack / Container visibility

• Manual process for Non conforming

material prone to errors

Solution


• Material Flow Replenish

• Scrap Tracking and

Management (STMS)

• Technology

• Active RFID Triggers

• Barcode Triggers

• Mobile devices

Solution Features

• Automated Pull Systems

• Supplier Portal

• Part Traceability

• Real time work instruction and

exception handling

• Electronic Scrap tags

• Automated inventory disposition

• Automated quality assurance process

for Vendor rejects

CASE STUDY TIER SUPPLIER:

FLOW REPLENISH

BEFORE

Material Flow Replenishment

AFTER

Material Flow Replenishment

Manual replenishment process Wireless replenishment process

Excess inventory Reduced inventory carrying costs by $750,000

Underutilized labor force Labor productivity up 20%

Underutilized equipment Equipment utilization up 30%

Excess waste (movement) One-third reduction in daily forklift trips

Frequent line-stoppages Virtually eliminated line downtime due to parts

Line side delivery shortages Lack of supply/demand visibility into internal and

external supply Improved plant floor demand visibility

OFF-LINE AND CONTAINMENT

Key Challenges

• Need for increased throughput in Off

Line area as production rates

increase.

• Improved visibility to rework areas /

consistent handling to improve quality

• Increased velocity in ship yards and

real time location of all vehicles

• Eliminate manual yard inventories

Solution


• Vehicle Tracking and

Management (VTMS)

• Visibility Software (VSS)

• Technology

• Active RFID

• Passive RFID

• Barcode

• Mobile devices

Solution Features

• Real time visibility to finished vehicles

• Rule based processing for Off Line

area

• Quality containment

• Alerting

LANDROVER: VTMS

BEFORE

Vehicle tracking

AFTER

Vehicle Tracking

No visibility to off line vehicles Real time location for all produced vehicles

Excess inventory of in process vehicles Reduced WIP vehicles by 20%

Manual process for yard inventory Automated process for re-work based on work

rules

Poor containment of re-work vehicles 100% containment of quality held vehicles

No visibility to orders vehicles after of line Real time location of all orders

High labor costs in Off Line Reduced 8 HCE

Summary

• The Internet of things is here, and will be

transformational for supply chain execution and

visibility

• Both active and passive RFID has an important

role to play depending on the problem we’re

trying to solve

• RTLS solutions provide Constant Visibility to

assets, materials, and people

Thank You!