Document

Case Study
Trakya Döküm Solves Real-time visibility of
molds with Xerafy RFID tags
TRAKYA DÖKÜM
Deploys RFID
Tracking moulds at its
foundry.
RFID tracking during
manufacturing process
via RFID tags inserted
into the product moulds.
The captured data is
automatically updated
onto the SAP
Manufacturing
Trakya Döküm is a world-class ISO/TS 16949 certified Disamatic foundry. It produces cast and machined
parts in all grades of ductile, grey and malleable irons destined for the automotive, white goods, construction
and other industries. It is the second-largest foundry in Turkey, manufacturing 80,000 different product lines.
Trakya Döküm lacked a real-time overview of manufacturing along its production line. This led to inefficient
under- or overproduction, poor inventory control, errors and duplication of work. It decided that the most
effective way to track production was to insert RFID tags into its moulds and scan these via RFID readers as
they are used during the manufacturing process.
Having also trialled another RFID solution, Trakya Döküm chose Zebra Technologies’ RFID readers due to
their price–performance ratio when compared with other UHF RFID readers on the market. It worked with
Zebra Technologies’ partner EHV IT CO on the deployment. EHV IT CO was one of the first RFID System
Integrators in Turkey.
www.xerafy.com
Solution Overview
Customer: Trakya Döküm
Partner: EHV IT CO
Application: Mould tracking
Xerafy tags: Pico Wedge
Reader: Zebra
Challenge
The foundry has a very complex manufacturing process,
with over 2000 moulds and 80,000 product lines.
Manufacturing operators had been manually entering the
number of the mould being used in the DISA Complete
Foundry Machine into the SAP Manufacturing Integration
and Intelligence (SAP MII) system. With the number of
moulds, variables to the products per mould and
machines currently in use at the foundry, this, inevitably,
resulted in occasional inputting errors and subsequent
manufacturing inaccuracies.
Benefits :
• Excellent RFID readability
• Real-time accurate production
overview
Solution
Trakya Döküm decided to deploy an RFID Solution from
Zebra Technologies. Installation of the RFID readers and
antennas took just one day. EHV IT CO also provided a
day’s intensive training for users. Following a rigorous
testing phase, the RFID solution went live. EHV IT CO
provides ongoing support and assistance.
Applying RFID tags to the moulds was an interesting
challenge in this project. Trakya Döküm wanted to embed
the tags directly into its moulds. However, the embedding
process would destroy most RFID tags.
• Improved manufacturing planning
• Greater inventory control
• Cost savings
• Increased staff productivity
www.xerafy.com
Trakya Döküm selected Xerafy™ Pico Wedge RFID tags, which were engineered specifically for embedding and
use in industrial environments. The tags are 24.2mm x 6.2mm in size and weigh just 3.7g. Each tag has its own
EPC number and the EPC is matched with the mould number, which is combined with the EPC number of the tag
in the SAP database.
Three to five moulds can be tagged daily. This is a challenge in itself as, although often only 100cm x 70cm in
size, the moulds can weigh between 100kg and 300kg each. The tags have to be inserted into the mould. A
23mm diameter drill piece is used to drill a 7mm deep hole. The tag is hammered into the hole and the surface
is then covered with a metal adhesive. The Pico Wedge tags are made from nylon polymer and certified to the
MIL-STD-810F standard for vibration resistance, so they can withstand the embedding process. The tags need
to be embedded near the top of the mould to ensure the tag can be easily read, but safely implanted in the
mould so they cannot fall out or be removed.
Secondly, the tagged moulds are utilised in the six DISA Complete Foundry Machines at Trakya Döküm’s
production plant. The fixed RFID readers are
installed on the top of the machines and
enclosed in a special case for protection.
Antennas, 6 – 9 metres long, extend from the
RFID readers to the glass cabinets where
production occurs. The glass cabinets allow
workers to monitor the moulds during the
process, as sand is poured between the male
and female moulds. The sand does not
penetrate the Pico Wedge tags and interfere
with performance because the have an IP68 rating and are completely sealed against dust. The antennas,
which are carefully positioned to be never further than two metres from any mould, read the tags embedded in
the moulds during the moulding procedure. Depending on the products that are to be manufactured, sometimes
just the male or female mould is tagged; in other cases both moulds are tagged and data is received from both.
www.xerafy.com
Finally, the data captured as the mould passes through the RFID reader is automatically updated onto
Trakya Döküm’s SAP MII system. The tag operation is completed in .NET and then also passed on to the
SAP ERP via RFC. In this way all parts of the business have a real-time manufacturing overview at all times.
The MC3190-Z RFID Handheld Readers are used for the scanning of tags when they are first attached to the
mould, for the initial upload of their ID to the database, before the moulds are used on the production line.
The handheld readers also allow the flexibility for production line workers to scan and upload the latest data
to the Tag ID during the manufacturing process, when the material and composition of the manufactured
product in the mould changes.
“We currently have six moulding lines. We can manufacture the same products
for days at a time on any one line. Or sometimes two, three or four different products
can be produced on a line in one day. It’s complex and constantly changing. RFID is
the only really effective way we have found of monitoring production. We have
eliminated inputting inaccuracies and reduced manual data input, so staff can be
more productive and accountable. We can also manage our inventory more
efficiently. And we know the solution is scalable as our business grows. All this cuts
costs.”
－－－－－－Deniz Okuyan, Procurement Manager and RFID Project Lead.
www.xerafy.com