Tips for Successful Implementation of RFID in Manufacturing

One of Argo Wireless’s partners, FactorySense, is an RFID solutions expert that works with many manufacturers to integrate RFID tracking systems that improve efficiency, visibility, and control. We asked them to share their RFID expertise with the rest of our partners, providing insights that can help share common RFID implementation challenges and the tips for successful RFID rollout.

Why the Implementation of RFID in Manufacturing Matters

In modern manufacturing environments time is money; even minor process inefficiencies can snowball into costly production delays. Time lost searching for raw materials, tools, tracking down work-in-process (WIP), or locating finished goods reduces throughput and increases operational costs. 

Engineers are also under pressure to advance toward Industry 4.0 objectives, yet progress often stalls without a technology backbone that delivers real-time visibility and data integration. When applied successfully, RFID provides that foundation, enabling precise asset tracking, streamlined workflows, and actionable production intelligence.

FactorySense has seen firsthand how pairing durable RFID tags, optimized RFID antennas, customized FactorySense RFID software and best installation practices can reduce losses, streamline workflows, and enable the data-driven manufacturing that Industry 4.0 demands.

Manufacturing Pain Points RFID Can Solve

• Lost assets and wasted time: Misplaced or lost tools, equipment, or components become lost time and lost profits. RFID ensures real-time tracking, reducing loss, downtime, and search efforts.
• Lack of visibility into the full manufacturing process: Without item-level tracking, it is difficult to locate thousands of raw materials, tools, WIP, or finished goods in real time.
• Product identification challenges: Differentiating between similar parts or SKUs is nearly impossible without unique identifiers.
• Post-production problems: Rework, recalls, maintenance, and compliance requirements that require accurate historical data for each item from source to customer.
• Industry 4.0 readiness: Legacy tracking methods cannot provide the automation and analytics that modern manufacturing strategies require.
• IoT data integration gaps: Without RFID feeding real-time location and status updates into IoT platforms, manufacturers miss the opportunity for automated alerts, predictive maintenance, and AI-driven decision-making.

RFID addresses these issues by embedding intelligence directly into assets, enabling real-time location from the factory floor to shipping docks.

5 Common Obstacles to Successful RFID Implementation

Even with proven benefits, RFID deployment in manufacturing presents some hurdles:

• Signal interference: Metal surfaces and liquids can disrupt signals. Selecting the right tag type and positioning antennas correctly mitigates these issues.
• Integration complexity: Connecting RFID data to existing MRP or ERP systems takes careful planning to ensure synchronization and compatibility.
• Environmental challenges: Extreme heat, cold, humidity, and chemical exposure require specialized RFID hardware built for harsh conditions.
• Upfront investment cost analysis: The cost of tags, readers, antennas, and infrastructure needs to be weighed against ROI.
• Data overload: RFID systems can produce large amounts of data. Without the proper RFID platform the information is useless.

Antennas and Installation: The Cornerstones of Performance

An RFID system’s performance depends heavily on antenna selection and installation. RFID antennas control the size, shape, and direction of the read zone. Poorly placed antennas may create “dead zones” or pick up stray reads, undermining accuracy. FactorySense emphasizes site surveys and modeling to identify optimal reader placement, typically choke points like entry/exit points or key areas where WIP process is transferred from one process to another to ensure consistent reads even in metal-heavy or high-traffic environments.

By using high-quality RFID antennas like the ones that Argo Wireless offers, you have the ability to directionally adjust the signal and achieve accuracy rates and can track thousands of items that make passive RFID automation practical. You typically don’t need to place RFID antennas everywhere in the warehouse.

Tips for a Successful RFID Rollout in Manufacturing

1. Start with a site survey: Identify where RFID can be used to deliver the biggest return, such as tool tracking, WIP visibility, or inventory management, or asset tracking and maintenance while following the KISS principle “Keep It Simple, Stupid”
2. Choose the right technology mix: Carefully choose passive and/or active tags as this decision can significantly impact ROI and maintenance. Match RFID tag, antenna, reader and software to your environment and application.
3. Invest in software: A robust RFID platform turns raw reads into actionable insights and can interface with the ERP and WMS system. FactorySense has a great software platform purposely built for manufacturing.
4. Lots of Training: FactorySense creates user manuals and hands-on training to help operators, facilities, and IT understand how the system works and why it matters.
5. Partner with an RFID expert: Attempting RFID implementation without specialized expertise can lead to costly mistakes. Partnering with RFID experts like FactorySense for installation, optimization and troubleshooting.