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planning, physics, pilot and
production. “The planning phase
focuses on how RFID will change
existing business processes; the
physics process focuses on using
science to determine the proper
strategy for tagging, readers and
systems; and then a four to six
month pilot determines if the
businesscase is proven”, says
Sweeney. “Following a successful
pilot and metrics comparison, the
system can then be scaled up to
production. We aim for a
12-month or sooner return on
investment (ROI).”
One of the phase one pilots, now fully implemented and saving
significant amounts of time, money and space, was based at the
final assembly plant for the A380, in Hamburg, Germany. RFID
tags are fitted to the containers that transport parts between the
logistics centres and the final assembly line. There are 750 of these
bulky containers needed per A380 and they are delivered across
four stories. “Manually tracking the location of such a high
volume of containers is very time consuming”, says Nizam, “If a
container is mis-delivered to the wrong location, the amount of
time it would take to find it can cause a lot of disruption. So it’s
vital to know that they are delivered at the right time to the right
place and didn’t get misrouted.” The containers all look the same
and are sealed so workers would only find out they have the wrong
one when they open it up which would be too late.
With the entire assembly line now wired up with 40 RFID readers,
and all 3000 containers tagged, Airbus has experienced significant
benefits from the use of RFID. “RFID allowed us to streamline the
process and automate it. It’s now a lot faster. Containers are
tracked automatically and delivered on time, at the right time, the
first time”, says Nizam. “That means we don’t need extra containers
to compensate for the lack of visibility, and they’re not cheap.
They also take up a tremendous amount of space. And if one ever
did get misrouted, then at least with RFID we can easily find it.”
Another phase one pilot was set up by Airbus with some of its
suppliers to label packages with RFID shipping labels. “We
worked with enough products and suppliers to give us statistically
valid data but without inducing too much risk”, says Nizam. “We
found the logistics processes were leaner, we achieved 100% data
accuracy, we drastically reduced the paper shuffling and hence cut
the physical handling time by between 65-70%.”
A380 final assembly
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Airbus Beluga transport aircraft
Featuring one of the most voluminous cargo holds of any civil or
military aircraft flying today, the Airbus Beluga, or A300-600ST
Super Transporter was developed to carry complete sections of
Airbus aircraft from different production sites around Europe to
the final assembly lines in Toulouse or Hamburg. To be loaded
into the Beluga, aircraft parts such as fuselages are first loaded into
jigs - in effect, very large, expensive and specialised packing crates.
“When the jig is delivered, the aircraft section is unloaded from it,
and the jig is now empty”, says Nizam. “On its next visit, the
Beluga will again offload new parts and should load up with empty
jigs from the previous trip.
All these activities need to be tracked in order to protect smooth
transport planning and supply to production lines. Today this
tracking is performed via paper and will become more difficult to
maintain as we ramp up our production rates. If the empty jig isn’t
where it should be, the aircraft can’t leave and this can ultimately
impact the production lines”, says Nizam.
Helping to solve this problem is the driving force behind one of the
pilots in Airbus’s phase two RFID rollout, which focuses on
automating and streamlining global transportation, production and
manufacturing processes. “We’re putting RFID tags onto the jigs
and installing readers on the cargo loaders that roll the jigs on and
off the planes at Hamburg. That information is sent via a wireless
network to our business systems, so the planner in the office can see
exactly what’s going on in real time. So far, the results from the pilot
are very positive and in line with expectations.”
Sheet metal tracking
Another candidate for a phase two pilot is sheet metal tracking at
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