Well-known chemical industry corporation pilot module for RFID-based FERTILIZER TRACKING SYSTEM

Transcription

1 Well-known chemical industry corporation pilot module for RFID-based FERTILIZER TRACKING SYSTEM Automatically and efficiently tracks fertilizer manufactured TECHNOLOGY Efficient batch processing and management Solution: Real-time inventory updation on conveyor belt itself EPC Gen2 compliant inventory tracking solution Tracks finished stock being taken out of the premises and tallies with stock received by distributor Tag Type: Genera UHF Passive Reader/Antenna: Xtenna Xtenna Hybrid HandyScanna Method: Multiple Tracking via Integrated Reader/Antenna modules Single Tracking via hand-held Integration Platform: RFID Middleware: Xtenna WebToolkit Xtenna Studio Application: Essen RFID s Inventory Tracking System Database: SQL Server 2005 Exp. ed. ERP: SAP Tag Manufacturer/Supplier: Essen RFID, with US based chip inlay Reader/Antenna Manufacturer: Essen RFID, with US based module Systems Integrator: Essen RFID INSIDE: Key Requirements Solution Implementation Working Benefits Links For further details contact: Essen RFID 24-B, Jolly Maker II Nariman Point Mumbai India

2 KEY REQUIREMENTS: Deepak Fertilisers (DFPCL) manufactures different types of fertilizer. These are then packed in bags of different quantities and sent to distributors. The company used a manual system for keeping records, which consisted of a manual count of quantities packed within bags, quantity of stock in the warehouse and quantity of bags sent for distribution. This was a very tedious and time-consuming task that had the following drawbacks: Incorrect inventory of finished product Inability to track missing or stolen inventory Time-consuming process Required more resources in handling, hence resulted in increased cost. These problems resulted in time wastage during manual count and tallying of fertilizer bags manufactured and distributed, since the system was neither efficient nor accurate. Hence the company required an automated system that could track fertilizer bags and provide real-time information on finished product inventory in the warehouse as well as along the distribution chain. SOLUTION: Essen RFID offered an automated solution for tracking fertilizer bags using RFID technology. This system efficiently tracks bags and maintains stock inventory. It involves the use of RFID tags, integrated antenna-readers and hand-held HandyScanna devices. The solution uses SQL Server as server database. The HandyScanna sends data to the server via Wi-Fi connectivity. IMPLEMENTATION: A GENERA RFID tag is attached to each fertilizer bag. The bags are registered into the database using Xtenna Hybrid. Xtenna antenna-readers are mounted at the entrance/exit of the unit premises. The warehouse uses HandyScanna to scan the stored inventory and send updated details to the server. 2

3 WORKING: The system works as follows: Process Flow: 1. Each batch of fertilizer manufactured consists of a particular type and packing weight, and bags of appropriate size are selected with batch numbers allotted accordingly. All bags used for packing fertilizer in various quantities are preattached with GENERA RFID tags. The tracking system software is configured to receive all required batch data inputs before production of that batch starts. 2. As each bag in that particular batch is filled with fertilizer, a conveyor system carries the bags from the manufacturing section to the loading area. The conveyor system has a Xtenna Hybrid antennareader device placed on either side of the belt. As each bag moves along the belt, Fertilizer batch details entry Product code Type and size of bag Composition Tag detected at conveyor Auto assign batch details to bags Save bag details in database Update the number of bags in stock inventory its tag is detected by the Xtenna Hybrid devices and the bag is automatically assigned to the previously input batch data. 3. The system simultaneously updates inventory and is thus up to date with the latest inventory stock information in real-time. 4. There are two conveyor systems, one for direct truck loading and the other for warehouse storage. A robotic arm places the fertilizer bags onto pallets which are then carried by forklift. 3

4 Forklift taking pallet containing 30 bags out through the RFID portal Tagged bags detected at portal LED counters updated at the portal for forklift driver to make sure he is taking all 30 bags Database updated for bags detected as OUT at warehouse In case all bags not loaded onto the truck Reverse inventory updation using HandyScanna for manual check IN at warehouse 5. The HandyScanna device is used for taking an inventory check of the warehouse, or for locating a particular batch or bag. To do this, the warehouse supervisor enters the search criteria into the HandyScanna touchscreen and scans the bags in the warehouse. When the search is positive and the batch or bag is found, it displays the result on the HandyScanna screen with an intimation for inputting the next process option. 6. When an outward order is received at the warehouse, the supervisor uses the HandyScanna to sort the fertilizer bags and readies them for truck loading in quantities of bags that are carried on a pallet by forklift. Take inventory count using the HandyScanna device Start scan using Take Inventory option in the HandyScanna menu Press the Green button for reading the tags Scan all bags needed for the inventory check Update the inventory of fertilizer bags in the warehouse with the new date and time of inventory taken 4

5 7. Each Entry/Exit gate at the premises has a portal erected with Xtenna RFID antenna-readers mounted on it. When the forklift goes through the portal, all tags which are attached to the bags are scanned and the tracking software checks their batch number and maximum manufactured count. A signal light and buzzer indicates to the forklift operator that all bags are scanned and the inventory has been updated. 8. When loading the truck, if the fertilizer bags are found to be more than the capacity of the truck, then a reverse inventory updation is done using HandyScanna for re-entry back into the warehouse. 9. If any fertilizer bag is damaged, then using HandyScanna the bag can be entered as rejected. The system will then update the rejected count in the database. 10. A distributor can also count and validate all received bags using the HandyScanna device, when delivery of fertilizer bags is received by him. If his count does not match the warehouse dispatch count, the system will flag the missing inventory details and send a report to the administrator. 5

6 BENEFITS: Automatically tracks the quantity of inventory in hand. Real-time visibility of fertilizer stock at any time. Tracks inventory going out from the warehouse to the distributor. Identifies inventory theft or misplacement. Efficiency and accuracy lead to improved process management. In-built alarm to stop batch production if there is mismatch. Automated reporting functions in system can identify total stock, rejected inventory and distribution. LINKS: Hardware: Tags: Software: Reference Example: 6