RFID in Manufacturing (eBook)

Oliver Günther has been a Professor and Director of the Institute of Information Systems at Humboldt University in Berlin since 1993. There he also directs the Berlin Research Center on Internet Economics (InterVal), and Humboldt's Interdisciplinary Center on Ubiquitous Information. He is President of the German-American Association for Scientific Cooperation in Computer Science and serves on the Advisory Board of SAP Research EMEA. Wolfhard Kletti has been working for MPDV Mikrolab GmbH since 1986. Today, as Vice President, he is responsible for the development of their Manufacturing Execution System HYDRA. Moreover he manages MPDV´s Program MES Services for SAP users, which provides the consultancy and MES software to integrate ERP in the manufacturing processes. Uwe Kubach joined SAP Research in Karlsruhe in 2002 and was one of the key initiators of SAP’s Smart Items Research Program. Since 2005 he has been the Director of the SAP Research Center in Dresden. In this role he is also responsible for coordinating SAP Research’s global activities in the field of Future Manufacturing including Plant-to-Business Integration.

Preface 5
Contents 8
Chapter 1 RFID in Manufacturing: From Shop Floor to Top Floor 16
1.1 Architectural Perspectives 16
1.2 RFID Basics and Standards 21
1.2.1 Technical Foundations 22
1.2.2 EPCglobal ™ 25
1.2.3 OPC and OPC-UA 28
1.2.4 ISA-95 29
1.3 RFID Potentials 31
1.3.1 Scanning 31
1.3.2 Tracking 32
1.3.3 Tracing 33
1.3.4 Metadata Management 33
1.3.5 Back-End Communication 34
1.3.6 Label Management 35
1.3.7 Inter-Enterprise Collaboration 35
1.4 Cost–Benefit Considerations and Adoption Decision 36
1.5 Summary 38
Chapter 2 The Role of Enterprise Software 40
2.1 Trends in Manufacturing and ERP 40
2.2 Enterprise Service-Oriented Architectures 41
2.3 SAP Software for Real-World Awareness 42
2.4 SAP Auto-ID Infrastructure 44
2.4.1 System Requirements 44
2.4.2 System Overview 45
2.5 Summary 49
Chapter 3 The Role of Manufacturing Execution Systems 50
3.1 Why an MES ? 50
3.2 Integrating MES into the Enterprise Information Infrastructure 52
3.3 Processes Relevant to MES in the Company 54
3.3.1 Time Scheduling and Sequencing, Shop Floor Control ( also refer to Sect. 3.7.6 ) 56
3.3.2 Intralogistics ( see also Sect. 3.7.3 ) 56
3.3.3 Quality Management ( see also Sect. 3.7.4 ) 57
3.3.4 Time and Attendance and Time Management Within Production ( see also Sect. 3.7.5 ) 57
3.4 Tasks and Functions of an MES 58
3.5 Data Collection During Manufacturing 62
3.5.1 Data Collection Station 63
3.5.2 Connection of the Automation Layer 64
3.6 Flow of Information 66
3.7 RFID and MES 67
3.7.1 Identifying Objects in Production 67
3.7.2 Realization of Online Interfaces 69
3.7.3 Intra-Enterprise Logistics 70
3.7.4 Quality Management 71
3.7.5 Access and Attendance Control 72
3.7.6 Shop Floor Control 73
3.8 Summary 74
Chapter 4 Six Case Studies 75
4.1 AIR: Airbag Manufacturing 75
4.1.1 Current Situation 76
4.1.2 RFID Perspectives 80
4.1.3 Costs and Benefits 85
4.1.4 Summary 86
4.2 CLU: Sliding Clutches 86
4.2.1 Current Situation 87
4.2.2 RFID Perspectives 90
4.2.3 Costs and Benefits 94
4.2.4 Summary 95
4.3 COO: Engine-Cooling Modules 95
4.3.1 Current Situation 96
4.3.2 RFID Perspectives 98
4.3.3 Costs and Benefits 99
4.3.4 Summary 99
4.4 CAS: Production of Cast Parts 99
4.4.1 Current Situation 100
4.4.2 RFID Perspectives 102
4.4.3 Costs and Benefits 104
4.4.4 Summary 105
4.5 CON: Production of Electronic Connectors 105
4.5.1 Current Situation 106
4.5.2 RFID Perspectives 110
4.5.3 Costs and Benefits 114
4.5.4 Summary 115
4.6 PAC: Aluminum Foils for Packaging 115
4.6.1 Current Situation 116
4.6.2 RFID Perspectives 122
4.6.3 Costs and Benefits 125
4.6.4 Summary 125
4.7 Summary 125
Chapter 5 Lessons Learned 127
5.1 Terminology 127
5.2 A Reference Model for Production 129
5.3 Motives for Using RFID 131
5.3.1 Accelerating Scan Processes 131
5.3.2 Extending Scan Processes for Quality and Efficiency 132
5.3.3 Extending Scan Processes for Narrowing Recalls 133
5.3.4 Reducing Paper-Based Data Management 133
5.3.5 Automating Asset Tracking 134
5.3.6 Reducing Back-End Interactions 135
5.3.7 Unifying Labels 136
5.4 RFID Versus Barcode 137
5.4.1 Monitoring Processes 138
5.4.2 Management of Process Data 138
5.4.3 Container Management 139
5.4.4 Uniform Labeling 139
5.4.5 Process Safety 139
5.5 A Guide to Assess Costs and Benefits1 140
5.5.1 Costs 141
5.5.2 Benefits 145
5.6 Basic RFID Functionalities 152
5.6.1 Filtering and Enriching RFID Data 152
5.6.2 Storing RFID Data 153
5.6.3 Sharing Information Along the Supply Chain 153
5.6.4 Event Detection 154
5.7 Requirements for the IT Infrastructure 155
5.7.1 Providing RFID Data to Components of ISA-95 Level 3 156
5.7.2 Distributing Business Logic and Data 157
5.7.3 Supporting Heterogeneous Data Sources 159
5.7.4 Dealing with Noise and Uncertainty 160
5.7.5 Supporting Process Analysis 160
5.7.6 Supporting Asset Tracking 160
5.8 Hardware Issues on the Plant Floor 161
5.8.1 Hostile Physical Conditions 161
5.8.2 Presence of Metal 162
5.8.3 Demand for Wireless Communication 162
5.8.4 Processes in Close Spatial Proximity 163
5.9 Current Motives and Open Potential for Using RFID 163
5.10 Summary 165
Chapter 6 Conclusions and Outlook 167
References 170
Subject Index 173