30,000 Metal Assets Tracked with RFID in the Biscuit Industry
In 2019, English Biscuit Manufacterers (EBM) deployed an RFID system to track approximately 30,000 metal assets.
All assets in 19 warehouses and two factories are identified with RFID technology. The implementation of RFID has improved audit efficiency of the 30,000 assets including production, packaging and storage equipment that are made of metal. With RFID, assets can be regularly maintained, inspected or replaced according to necessity.
English Biscuit Manufacturers (EBM), based in Karachi, Pakistan, was founded in 1966. The company produces desserts and snacks with a focus on quality nutrition and flavor. With market shares of over 48 %, EBM is also Pakistan’s leading biscuits manufacturer. EBM produces biscuits for the brands Peek Freans, Sooper, Cake Up and much more. Peek Freans biscuits are exported globally to the US, Canada, UK, Middle East and Africa.
Process Requirements
Thousands of metal assets for production, packaging and storage are essential for the production of the company’s products. These assets must be regularly maintained, inspected and replaced.
Traditional methods, including the manual annual auditing process was too time-consuming and inefficient. Employees had to physically check each asset and document the respective location, inspection and maintenance status on paper. The goal is to make audits more efficient and to reduce the waste from lack of visibility in production and shipping via a technology-based solution.
Objectives
- Improving asset audit efficiency and accuracy.
- Reducing waste in warehouses and factories.
- Facilitating asset maintenance, inspection and replacements according to necessity.
The EBM Solution
All metal assets are equipped with on-metal RFID tags that allow each asset to be identified at the production plant and at administrative sites. This includes fixed metal assets and the containers in which the finished products are shipped.
A regular physical audit of assets is possible over a large area with the use of handheld readers and an Android-based app. Operators carry the handheld reader through each area and data is automatically collected from the RFID tags. All missing and misplaced assets are immediately identified.
The system identifies which assets are present, as well as which tagged containers with loaded products must be shipped first, based on the date they were filled and placed in storage. First in first out processes are thereby ensured and unnecessary waste is eliminated.
The time required for asset audits is greatly reduced from a few days to a few hours. Annual audits are now possible quarterly, or even monthly.
Technology Partner
Hardware & Software
- Confidex - Ironside Slim RFID Tags
- Zebra Technologies - Handheld RFID Readers
Advantages
- Sustainability is achieved through the reduction of waste in the warehouses and production sites.
- Reduction in labor hours spent on the audit process.
- Audits can be conducted more frequently and at a higher accuracy.
- Potential for stock counting of raw materials upon goods receipt and at storage facilities realized.
Outlook
Applications can be expanded upon using RFID technology, including the provision of finished product SKU data, and warehousing information to ensure prompt and accurate shipping.
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