Al Hyrila

1
RFID Applications
in
Manufacturing
presented by

• Al Hyrila
• Engineering Supervisor
• Ford Motor Company

Steve Sordahl Senior Project Engineer Sandalwood
Enterprises
Advanced Manufacturing Technology Development
2
Overview

• The Need
• The Pilot
• The Results
• Next Steps

3
The Need

• Automatic Data Capture
• Part tracking
• Complexity management
• Manufacturing process control
• Traceability

4
The Need

• Reliability Specifications
• Similar costs as bar coding
• More reliable than bar coding
• More reliable than vision systems
• First time read rate 99.92
• Data accuracy 99.9997
• System uptime 99.77

5
The Need

• Other Specifications
• 128 bytes of read/write memory
• Read/write distance of 3 feet
• Anti-collision
• Globally accepted operation
• Operating temperature 40º to 200º (F)
• Withstand industrial fluids, motion shock
• Physical size smaller than credit card

6
The Pilot

• Goals
• Expand knowledge base of ADC techniques
• Test latest in ADC technology
• Prove reliability specifications
• Track key components during manufacturing

7
The Pilot

• Product
• Intellitag 500 RFID Tag
• 2.45 GHz

8
The PilotProcess
Eng Plant
Trans Plant
Eng Data
Trans Data
Vehicle Plant
Vehicle Data
9
The PilotEquipment

• RF Interrogator
• Antennas

10
The PilotEquipment
11
The PilotTags

• Tag Packaging Specifications
• Temporary
• Easy installation/removal
• Provide metal stand-off

12
The PilotTags
13
The PilotData

• Tag Data
• Unique tag ID 16 bytes
• Part Type 8 bytes
• Plant Location 5 bytes
• Tag Version 3 bytes
• Part Number 8 bytes
• Part Serial Number 16 bytes
• Time/Date Stamp 14 bytes
• 54 bytes

14
The Results

• Data Collection
• At every read/write location
• Record all tag data
• Record read/write status
• Audits for failure analysis

15
The Results
16
The Results

• Sources of Variability
• Tag packaging
• Part washer fluid
• Tag presence position

17
The Results

• Corrective Actions
• Design packaging better suited for the
  environment
• Maintain fixed position
• Repel water

18
Next Steps

• Harsh-Environment Packaging
• Permanently mounts directly to metal with
  adhesive, screws or rivets
• Water coolant resistant
• Physical size
• 82x10x8 (mm)

19
Next Steps

• Tag Attachment Options
• Adhesives
• No part modification
• Easy installation
• Difficult to survive harsh environment
• Mechanical
• Secure attachment
• Requires casting modifications

20
Next Steps

• In-process Uses - Machining

21
Next Steps

• Timing (2001)
• Attachment Development 1st Qtr
• Hardware Integration 2nd Qtr
• Reliability Testing 3rd Qtr
• Production Implementation 3rd Qtr

22
Next Steps

• Key Challenge Reduce Tag Cost!
• Drive down tag cost by using common tag packaging
  for a wide variety of applications

23
RFID Applications
in
Manufacturing
presented by

• Al Hyrila
• Engineering Supervisor
• Ford Motor Company

Steve Sordahl Project Engineer Sandalwood
Enterprises
Advanced Manufacturing Technology Development