How Printing Company Creates Real-Time Inventory For its Paper Material Management
Indonesian printing house deployed RFID based inventory management system in its paper material aging warehouse.
AAA provides various painting products for its customers all over Indonesia, they consumes plenty of paper material every day due to their intensive orders, and each order is unique with different requirement of paper, on time delivery of material and real time inventory are critical for AAA operation since production and material purchases were based on order entry and inventory status, current warehouse management is based on barcode system, it would provide real time inventory but it takes a lot of time for operators to manually scan the barcode, especially while the label is pasted at the opposite side, the operator has to go to other side to scan it.
RFID is proven to improve efficiency and reduce error during manual scanning, however, due to big volume consuming of paper material, disposal RFID tag will be costly for them, an easy attaching and detaching recycle RFID tag is required. Also, the paper is packaged in a roller, and covered by a kind of film, the challenge is that some of the material is made of aluminum while others are non-metal, then the RFID tag is required to be read both on metal and non-metal.
AAA approached to Moscad, an Indonesians RFID/SCADA system integrator with experience to deploy RFID solution in commercial and industrial environment. Moscad provides a whole SCADA solution to AAA, with rugged RFID reader and tag from Crepak. Moscad is chosen because they can provide whole SCADA solution and integrated it with AAA’s MES system, what’s more, they have rich experience of RFID for industrial environment.
As a strategic partner of Moscad, Crepak has been working with Moscad to provide WMS(warehouse management system), WIP(work in process) and asset tracking solution in Indonesian market, Crepak’s rugged RFID reader and industrial tag has been applied in transportation, manufacturing and logistic industry. For the AAA case, Moscad chose Crepak Optimus F240 reader with 2 antennas equipped on the top of warehouse gate. For recycle metal/non-metal tag, Crepak’s eTie lite with foam is perfect for this application, eTie lite is an economic and rugged RFID tag with ABS housing, by pasted a 6mm foam on the bottom, the tag then can be read on metal film, with adhesive on the other side of the foam, the tag would be easily mounted and removed from the roller.
“The reading was 100% accurate during the pilot, said by Steve, GM of Moscad.
The SCADA system was integrated to the AAA’s ERP system, the paper roller in and out of the warehouse gate can be automated identified by the RFID reader mounted on the top of the gate, and the information is shown on the screen installed on the wall. At the same time, SCADA system will send the information to ERP system and ERP system automatically change the roller inventory status. To prevent the system misjudging the paper roller in and out status, system integrator equipped two laser sensor in both side of the gate, the reader will only read while the sensor is triggered, if the outside sensor was triggered, system will judge that the roller is going into warehouse, If the inside sensor was trigged, system will judge that the roller is going out warehouse;
Additional benefit of RFID is that the system would know when and which paper roller are taken to production and which paper rollers are sent back or newly purchased per day, by comparing with daily, monthly and yearly output, paper consuming volume, the system can generate a report to see operation performance of each month, year.
One warehouse gate was chosen for POC in early 2019, it takes 2 weeks, the system runs stable and accurate, saved 30% delivery time, improved efficiency, so AAA deployed the system to all the 3 factories’ 6 warehouse. Tens of Crepak Optimus rugged UHF reader and thousands of Crepak eTie RFID tags are deployed. AAA is very satisfied with the solution and chose Moscad as exclusive solution provider to optimize the factory operation by using RFID technology.