RFID-based system for Lean Manufacturing in the context of Internet of Things

This paper describes the implementation of a manufacturing monitoring system using RFID, wireless, and plug-and-play technologies. The system gathered information about time and work in process (WIP), enabling process waste identification, production according to takt time, activity balance, and production capacity assessment. The method comprises the development of an RFID reader, a middleware, a database, and a software. The system is composed of Arduino micro-controllers, RFID readers, and wireless Zigbee transmission modules, enabling operations with real-time updates and mobility. The system was applied in two companies: one from the automotive sector, and the other from the energy sector, with different demands in operations management. In the automotive company, five readers were installed in one cell that manufactures yokes, and the results show that the process was not able to reach the takt time. In the energy company two reading points were used to analyze unproductive hours, which comprised 23.4% of the time spent. A reduction of 60% in man-hours was also verified in comparison to what was predicted in the energy company's budget.