Paper mills use RFID technology to optimize production and inventory management

For Brazilian paper companies that do not require identification, improving inventory visibility and speeding up production schedules are key requirements for their production plans. Therefore, the company invested in iTag’s RFID system. The system uses iTag’s tags and Acura’s readers to improve the operation process and production planning of paper companies.
Before the deployment of RFID, the papermaking process was carried out manually. Several workers performed a series of calculations on the output of each paper type, including different weights, sizes, and machine efficiencies, as well as scheduling specific shifts and operators. An executive of the factory said, “We did not make estimates of customer needs, such as monitoring customer orders based on paper type, weight and quality, so it is impossible to reduce costs through more efficient manufacturing processes.”

The purpose of this company is to produce only the products needed on the market based on consumption statistics. The executive explained, “We are currently applying the company’s internal and external management through the BI (Business Intelligence) integration of RFID solutions to achieve extensive data collection and data support, ensuring cost savings and increased flexibility in all processes.”
With the RFID system, the company has begun to know exactly what inventory is available for sale at any given moment. The executive said, “In many cases, this information comes from a knowledgeable employee’s inspection of the number of coils in the yard. Such an inventory survey may take 4 to 5 hours to complete.”
The difficulty of obtaining inventory information may have a knock-on effect on the production scheduling of new paper rolls. With RFID technology, companies can monitor the production date of specific coils, machine operators, paper type used, weight, and other variables. Now, all information is stored in smart tags.

At present, the import and export of inventory is controlled by RFID, which reduces the process of production control through manual tokens. The executive said, “We now have only one employee responsible for verifying data and reports. These data and reports put forward requirements for iTag services; we have also reduced the number of inspectors, and currently there are only two operators.”
The RFID process starts with the production of larger mother coils and then produces smaller daughter coils. At this stage, weigh and fill in all the information required for internal control. During the issuance process, the system automatically matches the label with the bus coil to avoid incorrect operation. Every time a label is released, the sales department will immediately learn that there is a new product available in the inventory, which will drive the picking process (the order is assembled through the RFID gantry before it is sent to the customer).

After the sorting order is issued and completed, the goods are separated from the inventory, you can generate invoices and documents by yourself, and fill in the weight and other data. This is all thanks to the integration with the RFID system, which not only ensures the efficiency of the operation, but also reduces the incidence of errors. The executive said, “After the deployment of the RFID system, the company has made progress in all areas of personnel, operation, and control. It can be said that the current operation method makes us feel very safe, and RFID has indeed met our expectations.”
The RFID system deployed by the company complies with GS1′s passive EPC UHF standard, and supports users to query product information from anywhere in the world through the electronic product code of the tag. The executive pointed out, “This will help export business, but also help customers generally recognize the product.”
An RFID gantry is installed in the project-specific structure, with antennas and eight readers, which are evenly distributed between the side brackets. All readers are from Acura and used with iTag’s sticky tags, which contain Impinj Monza R6 chips. The executive added, “We use 10,000 tags every month, and these tags cannot be reused.”

Post time: Sep-13-2021