Embed Size (px)
Citation preview
RFID for Materials Management
and Productivity Improvement
Todd Sutton
Business Unit Manager
Zachry Construction Corporation
FIATECH – Co-Champion
Element 4: Intelligent & Automated Construction Job Site
your logo here
RFID for Materials Management
and Productivity Improvement
• Most material available for implementing RFID
technology currently centers on the manufacturing
and retail industries.
• The benefits and true potential of implementing
this technology are virtually untapped by the
construction sector because the industry, as a whole,
has not yet realized the value it can provide.
your logo here
RFID for Materials Management
and Productivity Improvement
• The FIATECH Series of Innovation Guides for the
Capital Projects Industry
• “RFID for Materials Management and Productivity
Improvement “ is the first volume of a series for
implementing Technology on construction projects.
your logo here
Table of Contents
• Preface
• Acknowledgements
• Chapter 1 – Introduction
• Chapter 2 – Building the Business Case
• Chapter 3 – RFID Components
• Chapter 4 – Operating Standards
your logo here
Table of Contents
• Chapter 5 – Implementation
• Chapter 6 – Training
• Chapter 7 – Summary
• Appendix
• Glossary
your logo here
Chapter 1 –
Introduction
• Why RFID Technology
• What RFID Is and Does
• RFID Technology Versus Barcoding
• RFID Case Studies
• Overview of subsequent chapters
your logo here
Chapter 1 –
Introduction
your logo here
Chapter 2 –
Building the Business Case
• Materials Management Operations
• Supply Chain Operations
• Construction Site Operations
• Materials Management Methods and
Technologies
• Materials Management Project Control Systems
your logo here
Chapter 2 –
Building the Business Case
• Situation Awareness and Process
Streamlining
• Productivity Improvement Planning
• Analytical Approach to Current
Operating Flows
• Cost Benefit Analysis
• CPIP Checklist
your logo here
Chapter 2 –
Building the Business Case
your logo here
Chapter 3 –
RFID Components• Getting Started
• Bench Testing an RFID Configuration
• Tags
• Tag Implementation Construction Industry Example
• Interrogators
• Interrogator Implementation Construction Industry Example
your logo here
Chapter 3 –
RFID Components
• Interrogator Antennas and Cables
• Interrogator Antenna Construction
Industry Example
• RFID Software and Middleware
• Portals
your logo here
Chapter 3 –
RFID ComponentsFIATECH Smart Chips Project –
Field Trials of RFID Technology for Tracking Fabricated Pipe
ERP
SYSTEMMIDDLEWARE
RFID
READER
RFID
READER
RFID
READER
PRINTER/
ENCODER
OTHER
PERIPHERALS
your logo here
Chapter 4 –
Operating Standards
Regulations
Similar to Europe
EN 302-208
FCC 15.247
Still
Pending
Still
Pending
Regulations
Similar to USA
Region 1Region 2 Region 3
• Regulations and Standards
• Performance Impact
• Tag Size
• Tag Sensitivity
• Interrogator Interference
• Dense Reader Mode
your logo here
Chapter 4 –
Operating Standards
• Tag Interference
• Electrical Noise
• International Trade
• Standards
• References
-60.00
-50.00
-40.00
-30.00
-20.00
-10.00
0.00
10.00
20.00
30.00
40.00
866.3 866.35 866.4 866.45 866.5 866.55 866.6 866.65 866.7
Frequency
dB
m/1
00
kh
z
EN 302-208 Spectral Mask Limits
CW InterfererCarrier
Backscatter
Data IM Products
your logo here
Chapter 5 –
Implementation
• Implementation
• The Site Survey
• System Design
• Partner Engagement
• Installation
Fabrication Finishing
&
Cosmetics
Installation & Inspection
Various Storage and Laydown Areas
Receiving
&Shipping
A
B F
CY Z
Interrogation Zone
Programming Zones
Inspection
Storage
X
your logo here
Chapter 5 –
Implementation
• Technical Support and Services
• On-Site Training
• Expansion to other business areas
• Implementation Checklist
• Summary
your logo here
Chapter 5 –
Implementation Checklist
• The RFID Implementation Checklist was
developed to provide guidance when
implementing an RFID system.
your logo here
Chapter 5 –
Implementation Checklist
• This checklist should provide an outline
for implementation and can be easily
adapted to future requirements.
your logo here
Chapter 5 –
Implementation Checklist
Obtain Senior Management Support
Systems Integrator selection based on
primary implementation business
requirements.
your logo here
Chapter 5 –
Implementation Checklist Site Survey should consist of the following:
Onsite visit with systems integrator, site employees and IT Department network support representative walk through of current business process.
Perform electromagnetic spectral scan for potential sources of interference.
Perform the testing during peak operating times and over a 24-hour period.
Review legacy wireless installations and cellular networks.
Address electromagnetic generators on the construction site such as power tools and industrial fans.
Identify environmental conditions or constraints.
your logo here
Chapter 5 –
Implementation Checklist Document existing business process and review with system
integrator to determine what is to be tracked.
Determine the site infrastructure based on the site assessment by addressing the following:
Map out interrogation zone locations to assess the interrogation station and enrollment station requirements.
Tag type selection and assignment scheme
Tag placement
Mobile and hand-held readers selection
your logo here
Chapter 5 –
Implementation Checklist
Create Bill of Material for selected system
based on the site infrastructure
requirements.
Purchase System and start planning for
installation preparations.
Software systems integration with existing
systems.
your logo here
Chapter 5 –
Implementation ChecklistSetup equipment to improve process and
test infrastructure
Verify the ability to capture information and to transfer data to and from other systems.
Train employees on the technology and use of RFID to ensure proper tag placement on material.
your logo here
Chapter 5 –
Implementation Checklist
Partner with suppliers to verify system
compatibility.
Subject the system to load testing and use
during peak operation times.
Measure the results from the entire
process.
your logo here
Chapter 5 –
Implementation Checklist
Integrate the data between applications and
systems.
Have a contingency plan in place. Have work-
around and system redundancy prepared to
overcome technology issues.
Provide additional On-Site Training for
administrators and end-users.
your logo here
Chapter 5 –
Implementation Checklist
Go Live once all testing is completed and
monitor the RFID solution closely for the
first few weeks making any additional
adjustments as needed.
Review system and expand based on the
value added results of the initial
implementation.
your logo here
Chapter 5 –
Implementation
• This chapter focused on the implementation of RFID on a construction
jobsite to improve the tracking of the pre-fabricated pipe spools and
metal-marked steel parts. This chapter addresses the site survey,
system design, partner engagement, implementation, on-site training,
technical support / services and expansion to other areas or projects in
the corporation.
your logo here
Chapter 6 –
RFID Training
• The Evolving Pace of RFID Technology
• Why RFID Training Is Essential
• System Evaluation and Design
• System Optimization
• Industry Specific Training
your logo here
Chapter 6 –
RFID Training
• Who Needs RFID Training
• Types of RFID Training
• Expectations of Training
• RFID Training Checklist
• Summary
your logo here
Chapter 7 –
Summary and Outlook
• Defines the reason for the Book
• Summarizes the content of the Book
• Provides a future outlook of RFID
• Provides example of future application
your logo here
Capital Project Opportunities
• Construction Materials Produced Annually:
~30M* (Many items will Require Multiple Tags)
• Annual Labor Operating Inefficiency:
$61B to $122B**
© 2010 Reg Hunter, All Rights Reserved.
** Source: Advancing the Competitiveness and Efficiency of the U.S. Construction
Industry, Board on Infrastructure and the Construction Environment Division on
Engineering and Physical Science & 40% Labor Content Est. From EPC
* Source: Logistics Services Providers
your logo here
Productivity
Improvement Project
Awareness
What WAS Going On
• Fragile, Labor Intensive & Inefficient
• Delayed & Inaccurate Monitoring
• Reactive Decision Making “Fire Fighting”
• Work Harder Solutions
What IS Going On
Situation
Awareness
• Agile, Robust, Lean & Efficient
• Real-Time Monitoring
• Automated Real-Time Actionable
Information
• Rapid Excursion Detection & Recovery
• Proactive Decision Making
• Work Smarter Solutions
(End-to-End Visibility, Predictability & Control)
© 2010 Reg Hunter, All Rights Reserved.
Perspectives are Changing
your logo here
Systemic Inefficiency Example
Source: 2004 FIATECH-KBR Pipe Spool Locating
Study
• Meantime to Locate Using Grids: 6.7 Minutes
• Meantime to Locate Using GPS: 0.92 Minutes
• Efficiency Gain Per Locate With GPS: 5.78 Minutes
Assumptions:
• 0.92 Minutes Represents Travel Time
• On Average Materials are Located 3.5 Times
• Aggregate Labor Cost $300/hr
Operations Requiring Locating Materials
in Lay-Down Yards Using Grids vs GPS
Systemic Inefficiency Cost Implications:
Small Project: 15,000 => $ 1.5M
Large Project: 120,000 => $ 12M
© 2010 Reg Hunter, All Rights Reserved.
your logo here
Estimating Small Project Locating Inefficiency Costs
Total Number of Locate Transactions Performed in Thousands (000)100
05010 20 30 40 60 70 80 90
To
tal C
ost o
f In
effic
iency ($
)
125K
250K
375K
500K
625K
750K
875K
1M
1.250M
1.375M
1.5M
1.625M
1.750M
1.875M
2.00M
1.125M
52.5 (15,000 X 3.5 )
$1.517M
© 2010 Reg Hunter, All Rights Reserved.
your logo here
Bi-Monthly Costs Cumulative Project Costs
Systemic Inefficiency Costs
© 2010 Reg Hunter, All Rights Reserved.
your logo here
Locate Systemic Inefficiency Costs
© 2010 Reg Hunter, All Rights Reserved.
your logo here
Questions
RFID for Materials Management
and Productivity Improvement
Todd Sutton
