How US Automaker Enables Just-In-Time Assembly Line With RFID Work-In-Process

automobile manufacturing RFID solution
The US automotive manufacturer faced the challenge of maintaining uninterrupted production in a 24×7 manufacturing operation. The need for accurate real-time visibility into inventory and materials became crucial to support the company’s commitment to lean manufacturing, just-in-time processes, and Kanban systems.

Company

US Automaker

Industry

Automotive

Region

United States

Product

Cargo TRAK

System

RTP Inventory Tracking

Challenges

The existing manual processes relied heavily on human intervention, resulting in production delays, inaccurate inventory counts, and lost revenue. The customer sought an automated solution that could seamlessly integrate into their current manufacturing processes without disrupting workflow.

Solution

MSM Solutions, a leader in automatic identification, provided a tailored solution using their PortalTrack RFID replenishment system. The focus was on creating a real-time visibility solution utilizing RFID to track and visually report work-in-process replenishment inventory for a mission-critical automotive manufacturing operation.

To address the challenges, MSM Solutions integrated Xerafy’s Cargo OUTDOOR RFID hard tags. These durable metal mount hard tags provided reliable read ranges up to 20 feet, ensuring accurate tracking of assets within the manufacturing facility.

The RFID tracking system is built with:

  • Zebra FX7500 readers
  • Times 7 5010 flat panel antennas
  • CradlePoint IoT devices
  • Xerafy Cargo Trak RFID hard tags
  • 50″ flat-panel commercial monitors

MSM Solutions overcame security concerns, infrastructure costs, and the complexity of deployment by utilizing cloud-based software and IoT network technology. This approach reduced internal IT support, lowered costs, required zero maintenance for the end-user, and allowed for rapid deployment.

The implementation involved installing readers, cabling, mounts, cellular devices, and flat-panel monitors within a 2-day period. The PortalTrack customized software solution was live within 24 hours of hardware installation, providing immediate real-time visibility into production flows.

Results and Benefits

  1. Real-time visibility enabled smarter decision-making, ensuring production continuity.
  2. Improved inventory accuracy and prevention of lost revenue in mission-critical applications.
  3. Return on investment achieved in less than three months.
  4. Ongoing expansion of the project to more applications within the facility.

MSM PortalTrack’s visual inventory report provided real-time insights, including actual inventory counts, target counts, and total rack counts. Color-coded indicators facilitated quick decision-making based on inventory levels.

Due to the success of the initial project, MSM Solutions is piloting a new supplier-level project with the same automaker. The project involves managing the printing, encoding, reading, and analytics for an estimated 500,000 supplier totes at the receiving dock doors.

Xerafy’s Cargo OUTDOOR RFID hard tags, integrated with MSM Solutions’ PortalTrack system, have proven instrumental in optimizing the automotive manufacturing process. The case study highlights the significance of real-time visibility, RFID technology, and cloud-based solutions in achieving operational excellence and ensuring the seamless flow of production.

Xerafy is a pioneer in Industrial RFID, bringing to market several innovations that enable advanced industrial identification and automation capabilities.

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.

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