Seamless digital kanban,
powered by RFID technology.
Implemented at Turk Demir Dokum's Bilecik factory; the RFID Gate and Kanban system optimizes warehouse material preparation processes based on the pull methodology.
Line feeding optimization in boiler production
Turk Demir Dokum's Bilecik factory produces combi boilers. The project was implemented to optimize warehouse material preparation processes based on demands from production lines.
With the RFID gate application, the material flow has been transformed into a demand-driven digital kanban structure, synchronized with the production tempo.
Line feeding and order delays
Managing production line material needs with manual methods caused delays and preparation errors.
- 01Delay RisksDelays experienced in manual material ordering and preparation processes, risking line downtime.
- 02Inaccurate Orders & Excess StockIncorrect transfer of requirements leading to excess inventory or incorrect material feeding in the warehouse.
- 03Production Rhythm MismatchInability to synchronize the material flow with real-time production speed and line consumption rates.
RFID Gate & Pull Methodology
An RFID Gate application was implemented to optimize warehouse material preparation based on production line needs. More than 300 transport bins were RFID-tagged, automatically generating warehouse material orders as they exited through the RFID gate.
RFID Tagging
Over 300 transport boxes/bins are equipped with high-precision industrial RFID tags.
RFID Gate Scanning
Tags are automatically scanned as the boxes pass through the RFID Gate at the production area exit.
Automated Ordering
Scanned boxes turn into real-time order demands, auto-triggering material replenishment orders to the warehouse.
Handheld Terminal Control
Warehouse staff prepares and ships the correct parts error-free using RFID handheld terminals.
RFID and warehouse integration infrastructure
RFID Gate reading system
RFID antenna and transit gate positioned at the production area exit, scanning boxes in motion.
Industrial RFID tags
UHF RFID tags mounted on over 300 transport bins, resistant to harsh workshop conditions.
RFID handheld terminals
Mobile devices where warehouse staff performs material picking and transfer steps on-site.
OnSuite Trace Platform
Central software that converts RFID transit data into order demands and manages the process.
SAP ERP integration
Instant transfer of generated warehouse material order records to the SAP ERP system.
Digital Kanban Control
Pull control that triggers material flow according to the consumption rate of the production line.
SAP ERP Integration
The RFID Gate system runs instantly integrated with Turk Demir Dokum's SAP ERP; order records generated from field transits are automatically processed in SAP.
An automatic transfer order is created in SAP based on reading data of boxes passing through the RFID gate.
The status of boxes shipped from the warehouse to the line is updated instantly in SAP inventory.
Automated line feeding and optimized warehouse processes
Zero manual orders
Warehouse material preparation is automated with the RFID gate, completely eliminating manual order needs.
Pull methodology
Managing material flow according to the pull basis synchronized with production tempo prevented excess stocking.
Speed and accuracy
Maximum efficiency in warehouse material prep speed and shipment accuracy has been achieved thanks to the digital kanban structure.
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