Case Study

In the southern Pakistan, yarn manufacturer Nooriabad Textiles is using RFID tags to identify and locate spools of yarn in its warehouse.

Pakistan based Nooriabad Textiles, reportedly one of the largest single-site woolen spinner, has deployed RFID system to track spools of yarn in its warehouse at Nooriabad – an industrial location near Karachi. The new RFID system was designed and installed by Pakistan-based integrator QBSOLS Ltd.

The Challenges

 Missing of Yarn bags

Actual Yield Calculation.

Regular weight shortage complains

Tractability and tracking of quality yarn manufacturing

Nooriabad is using RFID to track spools of yarn in its warehouse.

At Nooriabad, around 2,000 RFID tags are used in the first phase of the deployment, which started in January 2015 and ended in March of 2017. At the company's warehouse, workers attach tags to bagged bundles of nine spools of yarn as they arrive from the manufacturing plant. Once tagged, the bundles are taken through an RFID portal and placed on storage racks to complete the receiving process. Data generated by the RFID system is collected by a middleware and stored in a Microsoft SQL Server 2005 database. This database holds the unique EPC number of each bag's tag, associating that number with a description of the bag's contents and its storage location. The middleware also links to Nooriabad warehouse management system.

RFID weighbridge system

The value of radio frequency identification (RFID) technology is critical for the supply chain, especially in the yarn industry, due to the high levels of complicated distribution processes and logistics operations in warehouse. RFID Solution is used at the handling process, such as: tracking work-in-progress, tracking inventories, counting stock, receiving, picking, and shipping of semi finished products. To do this, an architectural framework of the RFID-based information system for the yarn industry was designed, and a cost-benefit analysis was performed to further evaluate whether the new system is economical or not. Also risk analysis was performed for RFID investment.

 

To prepare an order for yarn, after weighing, a worker walks through the warehouse, pushing a mobile cart containing an RFID reader with an antenna mounted on an arm, a notebook computer and a wireless connection to the application server and the database server. This allows information such as tag ID number and yarn storage location to be exchanged. The system also aids the worker in picking the appropriate tagged bags of yarn from racks in the storage area. The bags are stacked on a pallet and their tags removed, after which the order is shipped to the buyer.

While the tagged bundles are in storage, Nooriabad will use the mobile cart to check stock automatically, pushing the cart through aisles in the warehouse to capture the tag number of each bundle.

Nooriabad expects that by providing the company with a real-time accurate inventory of the yarn it produces, the RFID system will help it reduce time and manpower resources for managing the stock in the warehouse, while accelerating sales and purchase decisions. Using RFID promises to reduce the stock-counting process from one full day to just in minutes of time, without any interruption to the warehouse operations.

Nooriabad will use the tags only within its own operations. "The tags do not store any meaningful information just sequential unique identifiers that match with the information stored in the back-end database.

Nooriabad may expand its RFID system to include a different category of bundle on another floor in the warehouse. The exact schedule for this, however, has not yet been finalized.

 

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