Evaluating the performance of a discrete manufacturing process using RFID: A case study

•We use an enhanced RFID system within a manufacturer’s shop floor.•We evaluate the workflow performance of a work layout redesign.•RFID data analysis through KPIs indicates bottleneck operations.•RFID middleware development improves data aggregation.•Improving workflow visibility advances manufacturing flexibility.

The material flow is a major focus point in improving productivity in today’s product diversified manufacturing organizations. Nevertheless, there is still a lack of efficient methods to control material flow through manufacturing processes in cases where multi-item tracking is difficult to achieve. This paper presents an RFID-based RTLS (Real-Time Location System) solution for obtaining multi-item work-in-process visibility within a manufacturer. It delivers detailed performance metrics through RTLS data analysis in order to evaluate workflow performance and to obtain a lean process. We pre-filter the RTLS data through the development of a middleware data collection method to acquire near real-time performance evaluation. A case study illustrates the complete process including measurements before and after a workflow redesign. The increased level of detail from RFID measurements yields new insights into shop floor actions and the real effects of redesign efforts.