RFID Case Study: Enhancing gas cylinder logistics with RFID technology

Eximia S.r.l., a leading system integrator, partnered with a prominent Italian industrial and medicinal gas producer to optimize gas cylinder management through RFID technology. The project aimed to enhance operational efficiency, improve traceability and streamline logistics across multiple production plants. This case study outlines the successful implementation of an RFID solution to address these challenges.

Challenge

The gas producer faced significant hurdles in managing approximately 40.000 gas cylinders across its extensive network of production units and commercial branches. Precise tracking, integration with existing ERP systems, and the ability to withstand harsh industrial environments were key challenges in finding a suitable solution.

Solution

Eximia implemented a comprehensive RFID solution utilizing its RFID software plattform: ERAM (Eximia RFId Asset Management), Eximia Middleware and android Apps for mobile devices. The solution's primary elements included:

RFID Tags: After extensive testing , Eximia chose Confidex Steelwave Flex RFID tags for their robust performance in harsh industrial conditions. These tags, which are Passive UHF EPC Gen 2, were attached to each gas cylinder to ensure durability and reliable tracking.

Two RFID gateways efficiently handle product movements:

Filling Area Reading Point: This reading point is engineered for installation in production environments, specifically at the filling station where it identifies cylinders during filling operations. It is designed to operate effectively even in complex environmental and operational conditions, such as areas exposed to humidity. The installation avoids unwanted readings, like cross-reading, maintaining process integrity. The filling area reading poimt is equippd with an Impinj R700 reader and 4 Times-7 A5060 antennas.
Eximia inbound/outbound RFID gates: This gateway, equipped with 4 Kathrein WRA3070 antennas and an Impinj R700 reader, is strategically placed at both the entry and exit points of the plant. It automatically identifies and tracks gas cylinders as they move in and out carried on trucks, updating their status in real-time. This setup optimizes the accuracy of cylinder tracking, ensuring efficient and reliable processing.

Handhelds: Operators at the site use rugged handheld RFID UHF readers with Android operating systems and Eximia logistic apps, designed for industrial usage. These readers allow operators to perform tasks such as identification, inventory management, asset handling and locating assets by scanning RFID UHF tags on gas cylinders. Data collected by the readers is transmitted to the Eximia software Plattform via Wi-Fi or GPRS network.

Software and System Integration: The RFID system is distinguished by its plug-and-play architecture which allows for real-time integration with the Middleware/ERAM Eximia platform. This integration is fine-tuned to enhance tracking efficiency, reduce errors, and increase overall productivity. Moreover, the system is fully integrated with the customer's Oracle Applications ERP, ensuring consistent data synchronization and streamlined plant operations.

Proof of Concept and Scalability

The initiative began with a proof of concept at one facility to evaluate the system's viability and effectiveness. This initial stage offered critical insights, allowing for tailored adjustments to optimize the deployment strategy.

Results

The project led to significant improvements in operational efficiency and accuracy. The key results included:

Streamlined logistics management: The processes for picking, packing, shipping and receiving were made much faster and more accurate, improving overall logistics control and tracking.
Enhanced production tracking & control: Production tracking and control were significantly enhanced, leading to more efficient and well-organized production operations.
Improved inventory management: Stock tracking was greatly improved, making it easier to search for, locate and manage inventory, reducing time and errors in stock management.
Enhanced safety in gas cylinder handling: Security measures for handling gas cylinders were strengthened, reducing risks and ensuring safer operations.

These improvements resulted in a more efficient, accurate and secure operational environment, meeting the project's goals and delivering substantial benefits to the customer.

Conclusion

The proof of concept not only demonstrated the RFID solution's capacity to improve operational efficiency and cylinder traceability but also established a scalable model for extending these advancements to ten additional plants. This project highlights Eximia's effective use of RFID technology in industrial applications, setting a new standard for gas cylinder logistics and positioning the company for future growth and enhancements.

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