Manufacturing logistics and packaging management using RFID

The chapter is centred on the analysis of internal flow traceability of goods (products and/or packaging) along the supply chain by an Indoor Positioning System (IPS) based on Radio Frequency IDentification (RFID) technology. A typical supply chain is an end-to-end process with the main purpose of production, transportation, and distribution of products. It is relative to the products’ movements from the supplier to the manufacturer, distributor, retailer and finally to the end consumer. Moreover, a supply chain is a complex amalgam of parties that require coordination, collaboration, and information exchange among them to increase productivity and efficiency [1, 2]. A supply chain is made up of people, activities, and resources involved in moving products from suppliers to customers and information from customers to suppliers. For this reason, the traceability of logistics flows (physical and information) is a very important issue for the definition and design of manufacturing processes, improvement of layout and increase of security in work areas. European Parliament (Regulation (EC) No. 178/2002) [3] makes it compulsory to trace goods and record all steps, used materials, manufacturing processes, etc. during the entire life cycle of a product [4]. According to the European Parliament, companies recognize the need and importance of tracing materials in indoor environments. Traditionally, the traceability system is performed through the asynchronous fulfilment of checkpoints (i.e. doorways) by materials. In such cases, the tracking is manual, executed by operators. Often companies are not aware of the inefficiencies due to these systems of traceability such as low precision and accuracy in measurements (i.e. no information between doorways), more time spent by operators and costs (due to the full-effort of operators who have to trace target positions and movements). According to [5] every day millions of transport units (cases, boxes, pallets, and containers) are managed worldwide with limited or even with lack of knowledge regarding their status in real-time. In order to overcome the lack of data due to traceability, automatic identification procedures (Auto-ID) could be a solution. They have become very popular in many service industries, purchasing and distribution logistics, manufacturing companies and material flow systems. Automatic identification procedures provide information about people, vehicles, goods, and products in transit within the company [6]. It is possible to note several advantages using an automatic identification system such as the reduction of theft, increase of security during the transport and distribution of assets, and increase of knowledge of objects’ position in real-time. Automatic identification procedures can also be applied to packaging products, instead of to each item contained in the package. Packaging is becoming the cornerstone of processing activities [7]. Sometimes products are very expensive and packages contain important and critical goods (for example dangerous or explosive materials) and the tracking of goods – and packaging in particular – is a critical function. The main advantage of automatic system application to packages is the possibility to map the path of all items contained into the packages and to find out their real-time position. The installation of automatic systems in packages allows costs and time to be reduced (by installing, for example, the tag directly on the package instead of on each product contained inside the package). The purpose of the chapter is to provide an innovative automatic solution for the traceability of everything that moves within a company, in order to simplify and improve the process of logistics flow traceability and logistics optimization. The chapter deals with experimental research that consists of several tests, static and dynamic, tracing the position (static) and movements (dynamic) of targets (e.g. people, vehicles, objects) in indoor environments. In order to identify the best system to use in the real-time traceability of products, the authors have chosen Real Time Location Systems (RTLSs) and, in particular, the Indoor Positioning Systems (IPSs) based on Radio Frequency IDentification (RFID) technology. The authors discuss the RFID based system using UWB technology, both in terms of design of the system and real applications. The chapter is organized as follows: Section 2 briefly describes IPS systems, looking in more depth at RFID technology. After that the experimental research with the relative results and discussion are described in Section 3. Section 4 presents an analysis of RFID traceability systems applied to packaging. Conclusions and further research are discussed in Section 5.