Active RFID technology enables manufacturer to
cut costs by using the technology to monitor vehicles in its yard after
production. Manufacturer seek a method for expediting the
movement of vehicles from the assembly line to shipping but at the same time making
sure that correct processes are adhered to.
In
contrast to manual processes, RFID will prove to be a very effective solution
for tracking vehicles within the storage yard. The solution reduces the
amount of labour needed to track vehicles in its yard, as well as ensuring
vehicles aren't shipped at the wrong times. Typically vehicles are built based
on dealership orders and assigned a vehicle identification number (VIN),
usually associated with a specific dealership, before they even come off the
assembly line. Therefore, tracking each individual vehicle before it is shipped
is critical. After the vehicles come off the assembly line, they undergo a
series of procedures and are moved to various locations around the yard, making
it difficult to pinpoint them. The RFID solution simplifies the process of
locating vehicles that need to be tested, serviced, stored or shipped, by
tracking each vehicle's location history and status.
The most notable benefit is the increase in labour productivity, by being
able to physically locate vehicles accurately based on varying criteria. Such
criteria can include searching for vehicles with a specific VIN, or a
particular part or model number. Using RFID, it manufacturer are able to minimize the time between off-track and dispatch,
thus maximizing this portion of the order-to-cash process.
When a vehicle has completed assembly, an RFID tag is
hung from the rear-view mirror or attached to the vehicle's interior door
handle. The tag's unique ID number is linked to the vehicle's VIN in the
backend system. The tag's beacons at pre-defined
intervals as the vehicle leaves the assembly line and moves first to testing,
then to repair or to the storage yard, where it passes through several portals.
At that time, Active RFID Reader will capture its movement from one area to
another.
The system provides the manufacturers with the vehicles' real-time location
based zone tracking. The backend tracking software enables the manufacturer to view a vehicle's
location on a graphical map (typically an uploaded DWG file) within a parking slot space to within 10 metres.
During the launching of new vehicle models, manufacturers typically
builds up several weeks' worth of inventory prior to shipment. At such times,
the tracking of vehicle quality (whether it needs additional work) and location
becomes even more difficult due to the high volume of vehicles.
The yard staff will then be equipped with industrial RFID-enabled handheld terminals, on
which they can access data as to which vehicles need which particular action,
thereby saving the employee a trip back to the office to check in with
supervisors. Workers can also use the device to locate a shipment by reading
the tags on the vehicles themselves.
If a vehicle in the shipping yard requires servicing—for instance, if a
supplier indicates a faulty part needs to be replaced—the vehicle is put in
"quality hold" status in the software system, which places a
"logical lock" on the vehicles. If someone attempts to ship the
vehicle before the removal of the locked status, the employee manning the
plant's exit gates will see the quality hold on his own PC, and will not allow
the vehicle to leave the premises.
Eventually,
the RFID system could be enlarged to keep
track of the movement of auto frames in the whole plant and its transition from
one production line to the next, namely the Body Shop, Degreasing Line, Paint
Shop and Final Fitting Shop; it is not limited to the storage yard. The unique
ability of the RFID tags to withstand the harsh environment present (especially
Degreasing and Paint Shop Oven) ensures the accurate data flow throughout the
manufacturing process. For these types of applications, a ruggedized high temperature tags would be required to withstand the paint shop process.
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