The company’s power systems assembly site in the UK relies heavily on manual engineering processes to fulfill custom orders. This posed significant challenges, from inefficiencies in tool inventory management to safety risks linked to damaged or misplaced equipment. Recognizing these issues, the company elected to deploy smart RFID lockers and automated tool inventory systems with Xerafy’s RFID tool tracking technology. These solutions not only address operational inefficiencies but also establish a new benchmark for safety and accountability in the manufacturing environment.
The company’s decision to remain anonymous reflects the competitive advantage gained through these innovative operational improvements, showcasing the transformative potential of RFID-enabled tool tracking automation in engineering workflows.
Challenges with Manual Tool Inventory Management
The manufacturing site operated in a highly manual engineering environment, producing high-horsepower engines and generator sets (gensets) tailored to specific customer requirements.
This complex production process necessitated extensive use of lifting equipment like bolts, shackles, and harnesses, and assistive devices to handle heavy components, such as winch-like machines for precise alignment tasks.
Despite the critical role of these tools, the company relied on manual processes to manage them, resulting in several inefficiencies:
Inefficient Lending and Returning Process: Manual tracking methods led to delays and wasted time.
Lack of Audit Trail: Absence of a comprehensive tracking system increased the risk of tool misuse, loss, or theft.
Safety Risks from Damaged Tools: Identifying and addressing damaged tools was slow, jeopardizing safety and operational efficiency.
Operational Bottlenecks: The manual processes strained the maintenance team, creating unnecessary delays and resource inefficiencies.
To address these challenges, the maintenance team sought an automated solution to streamline tool inventory management, improve tool tracking practices, and enhance overall safety and efficiency.
Integrated and Automated RFID Tool Inventory Management
The automated tool tracking system is built on intelligent RFID lockers that enable real-time tracking of tools and lifting gear. These lockers’ configurations are fully customizable, ensuring adaptability to the unique requirements of heavy machinery manufacturing. They feature seamless integration with existing company systems for data logging and procurement.
Key Features of Smart RFID Lockers:
RFID-enabled lockers allowing for real-time tracking.
Fully customized locker configuration with large compartments and small drawers.
Data integration and synchronization via 4G modem connection.
Card reader for easy login.
By combining advanced asset tagging solutions and automation, the system enhances operational workflows. Technicians benefit from pre-booking capabilities, while the smart system ensures tools are fit for use, damaged equipment is isolated, and repairs are efficiently logged. This approach reduces downtime, improves safety, and streamlines inventory management processes.
Technicians can pre-book tools and kits.
Capability for adding comments to tool records.
Automatic identification of fit-for-purpose kits.
Damaged tools are kept locked until repairs are completed.
Moreover, integration with company systems for data logging breakdowns and raising purchase requisitions helps automating the reporting process. This feature supports faster identification and resolution of equipment issues and streamlines procurement workflows, minimizing downtime and supporting seamless tool management across the manufacturing site.
Xerafy RFID Tool Tagging Solutions
Xerafy brings its deep domain expertise in tool tracking solutions, developed through extensive experience in critical industries such as aerospace (tool control to prevent FOD, Foreign Object Debris) and oil and gas (operational safety for lifting equipment).
The company’s tool tagging solutions address the specific challenges of managing critical tools and lifting equipment in manufacturing environments. Xerafy’s RFID tags are engineered with materials that withstand extreme temperatures, vibrations, chemicals, and physical wear, making them ideal for heavy-duty applications. Moreover, the tagging solutions accommodate a variety of tool sizes and materials, including metal, composites, and plastics, ensuring precise inventory control at an item level:
For Bolts and Shackles exposed to extreme mechanical stress, embedded RFID tags are recommended to prevent dislodging during operations.
For Winches and Power Tools, retrofit with rugged or simpler durable RFID tags.
- For Harnesses and Slings, attach fobs or hang tags for easy scanning and quick reusability.
Passive UHF RFID tags have become a preferred choice for tool tracking applications due to their superior performance characteristics. With an extended read range, large data capacity, and reliable functionality even in cluttered industrial settings, these tags address critical challenges in manufacturing environments.
Based on the passive RAIN RFID standard, these tags ensure seamless compatibility with industrial software and hardware used for inventory tracking. This interoperability enables the integration of RFID systems into existing workflows, enhancing operational efficiency and data accuracy. Their adoption has been further driven by the increasing demand for precise, scalable, and cost-effective tool tracking solutions in industries requiring high levels of safety and accountability, such as aerospace, oil and gas, and heavy manufacturing.
Key Advantages of Automated RFID Tool Inventory Management for Manufacturing Efficiency
The implementation of the company’s automated RFID tool tracking system has delivered measurable benefits, elevating tool management processes to new standards of efficiency and safety:
Precise Inventory Management: Each tool is uniquely identified with an RFID tag, providing real-time insights into its usage, availability, and location. This precision eliminates inventory discrepancies and ensures tools are always accounted for.
Increased Accountability: The electronic audit trail records every movement of tools, reducing incidents of loss or misplacement. The system ensures that each user’s actions are logged, fostering responsibility and transparency.
Enhanced Safety Protocols: Damaged tools are swiftly identified and isolated from operations, mitigating potential safety hazards. This proactive approach supports the implementation of safe systems of work and regulatory compliance.
Improved Operational Efficiency: Automation streamlines the lending and returning process, saving time and reducing workflow bottlenecks. Maintenance teams can allocate resources more effectively, enhancing productivity.
Rapid Return on Investment: The efficiency gains and cost savings achieved through automation lead to a quick ROI, demonstrating the tangible value of the system in a demanding manufacturing environment.
Xerafy is a pioneer in Industrial RFID, bringing to market several innovations that enable advanced identification and automation capabilities in Manufacturing.
In addition to a complete range of field-proven RFID tags available off-the-shelf, Xerafy offers Custom RFID Tags services, covering everything from a personalization service bureau to custom-design engineering capabilities.
