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Design and Develop an RFID based E-kanban Reordering System

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on 13 January 2015

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Transcript of Design and Develop an RFID based E-kanban Reordering System

Contents of the Journey
Problem Statement
Aims and Objective
Justification of Research
Literature Review
Concept Design and Research Methodology
Final Design and System Implementation
Evaluation and Testing of Proposed Design
Sustainable Development
Ethical Consideration
Project management

Justification of Research
An RFID based E-KANBAN Reordering System is a information system that will be able to improve/sustain the JUST IN TIME (JIT) practical in the warehouse management.

In future, the use of RFID technology can automated the information collection in the reordering system.

Upgrade/improve the reordering operation by optimize effectiveness and reliability of information for inventory control, reduction of duplicate work and human mistake.

Establish and improve the “Lean Culture” within the company by implement the kanban pull system.

Literature Review
Introduction to “Lean manufacturing”

Kanban system
Kanban card system
Comparison between Kanban card system and Current used Reorder point strategy

Electronics Kanban System
RFID Technology based E-Kanban System
Barcode based E-Kanban System

Comparison between RFID and Barcode Technologies

Automated Storage and Retrieve System (ASRS)

Small Scaled Conveyor System
Sustainable Development
Project Management
Total Project Expenses
Moral Professional and Ethical Consideration
The only concern of ethical issue from this system is that the kanban system will need the support from a very strict culture of LEAN such as Just-In Time (JIT), Kaizan (continuous improvement), Kanban (Pull system), 5s (Sort, Stabilize, Shine, Standardize, Sustain) and so on

the warehouse worker should not trigger the kanban signal to the system while the material is not yet reach the reorder level.

handling of kanban tag must be placed at the correct location to prevent the loss of RFID tag, and if there is the loss of RFID tag worker should report the lost at the very first time
Summary of Synthesis and Evaluation of the Present Project
It is important to highlight and emphasize again the intention of this present project which it is aim to designed an RFID based E-kanban system to eliminate the existed wastes in the material reordering system

Automate the routine works in day to day reordering operation in warehouse management helped to improve the quality of warehouse information by eliminate the human mistakes and wastes in process.

Automated real time detection of the reorder point of material.

Automated FIFO arrangement, Automated electronic kanban signal send through wireless.

Improve the accuracy of warehouse information, optimized lead time, cost, space of the warehouse management process and environment.

Achieve the Just In Time (JIT) concept of the lean manufacturing as to ensure the supplies of the right material is ready to serve at the right location with the right quantity and at the right time.


Anthony L. Patti. & Anthony Narsing., 2008. ‘Lean and RFID: Friends or Foes? ’. Journal of Business & Economics Research. Vol. 2. pp. 83-90.

Suprasith Jarupathirun., et al., 2011, ‘Supply Chain Efficiencies through E-Kanban’, International Journal of the Computer. Vol. 19(1). pp. 40-44.

Suwat Nanetoe & Nitipong Soponponpipat, 2013, ‘Optimum Design and Cost Characteristic of Small Conveyor’, American Journal of Apllied Sciences. Vol 10(1). pp. 15-23.

Y. SUGIMORI, et al., 2007. ‘Toyota production system and Kanban system Materialization of just-in-time and respect-for-human System'. International Journal of Production Research. Vol. 15(6). pp. 553-564.

Design and Develop an RFID based E-Kanban Reordering System for Raw Material Monitoring

Industrial Supervisor : MR.Chew Eng Lee (KPI)


Problem Statement
Aim and Objectives
Evaluation and Testing of Proposed Design
Contribution to the Project
Final Design and System Implementation
Concept Design and Research Methodology
King plastic Sdn. Bhd is plastic bottle manufacturing industry that was established in 1996, and produced 68 million bottles per annum, it has running more than 20 blow molding machines and 10 injection molding machines in the industry.

Real time problem found in KPI’s warehouse management for Master-batch.

Too many manual activities in the reordering process, which it has generated the human mistake/Error within warehouse’s operation and provided the subjective/inaccurate inventory information.

Wrong inventory information sent to suppliers and it had caused the wastes of time, processes and cash flow to reorder the extra or unnecessary material.

Problem Statement
Exceed Inventory, caused the high maintenance in warehouse.

Arrangement of the extra reordered material has caused unnecessary wastes in man power and spaces in warehouse.

The production would stop/delay while material shortage as the wrong information material send the supplier.

Time consumed for the FIFO arrangement of material on the shelf, wrong placing of material will cause the FILO happened.

Lack of LEAN Manufacturing Culture in Warehouse Enviroment

The warehouse management team can not ensure the supplies of the right material are ready to serve at the right location with the right quantity and at the right time.


The aim of this project is to design and develop an RFID based E-KANBAN system to improve the raw material (Master-batch) warehouse reordering system in King Plastic Sdn. Bhd.


To design an automated reordering system by developing an RFID based E-KANBAN control system.

To enhance and sustain the accuracy of the updatable data of raw material and establish the well communication between inventory and suppliers.

To reduce duplicate works done by warehouse operator and eliminate/minimize the human errors within the process of Re-ordering system.

RFID Based E-Kanban Reordering System and Automated Shelving System
Design of Graphical User Interface (GUI)
Ultrasonic Sensor System for Reorder Level Detection

Light Indicator System (Kanban instruction)

RFID system

Xbee wireless communication system between Arduino and Matlab

Graphical User Interface

Control of DC Geared Motor

Fabrication of Components and Parts

Hardware Implementation
Ultrasonic system
Kanban instruction
RFID System
Control System of DC Geared Motor
Conveyor System
Investigation on Material/component
Concept Design Derived From Fundamental Engineering Principles
Ultrasonic Distance Measurement Testing

Photodiode Sensor Interference Testing

RFID Reading Range Testing

Xbee Modules Wireless Communication Range Testing

Conveyor System Performance Testing

Estimated Budget Analysis
Final Project Gantt Chart (Phase 1 & 2)
Design a new idea/method of Kanban Pull System that can solve the existed problem in the respective company and its warehouse’s reordering system.

Study all the possible constraints and uncertainties that would affect the implementation and performance of kanban system as well as to know the manufacturing culture such as handling of material flow and documentation flow.

The study of existing method and unique solution that using RFID technology in the other application is important as the RFID technology is considered a high cost investment to the company.

LEAN has been transferred to the warehouse management team/workers in order to give them the idea of how the kanban system would assists and sustain their daily work load in the easier way
Conference Papers

Ahmad Naufal Bin Adnan, et al., 2013, ‘Implementation of Just in Time Production through Kanban System’, Industrial Engineering Letters, Selangor, Vol.3. pp. 11-21.

Carlos V. Carvalho, et al., 2013, ‘An innovative Framework for Lean Manufacturing training’, international Conference of Portuguese Society for Engineering Education (CISPEE), Porto, Oct. 31 – Nov. 1, pp. 1-5.

Chandandeep S. Grewal., et al., 2010, ‘Robustness-based Comparison of Reorder Point and Kanban Replenishment Strategies’, World Congress on Engineering. Vol.3, London, June. 30 – July. 2, pp 1-6.

Dimitrios Bargiotas, et al., 2009, ‘A scalable low-cost automated storage & retrieval System’, 16th International Conference on system, signal and image processing, Chalkida, 18-20 June, pp. 1-4.

I.A. Kouri., et al., 2008, ‘The Principles and planning of an electronic kanban system’, 19th International Conference on Production Research, Netherlands, pp. 99-104.

Li Minbo., et al., 2011, ‘A RFID-based Intelligent Warehouse Management System Design and Implementation’, IEEE International Conference on e-Business Engineering, Beijing, 19-21 October, pp. 178-184.

M.M. Rashid., et al., 2011, ‘New Automated Storage and Retrieval System (ASRS) Using wireless communications’, 4th International Conference on Mechatronics (ICOM), Kuala Lumpur, 17-19 May, pp. 1-7.

Silvanus T. Enns., 2007, ‘Pull-Replenishment Performance as a Function of Demand Rates and Setup Time under Optimal Settings’, Simulation Conference, Washington, 9-12 December, pp 1624-1632.

Sun Hong-ying, 2009, ‘The Application of Barcode Technology in Logistics and Warehouse Management’, First International Workshop on Education Technology and Computer Science, Wuhan, 7-8 March, pp. 732-735.

Tobias Kruhn., et al, 2010, ‘Decentralized Control for Small Scaled Conveyor Modules with Cellular Automata’, International Conferenceon Automation and Logistics, Hong Kong and Macau, 16-20 August, pp. 237-242.

Weixing Su., et al., 2009, ‘A Research on Integrated Application of RFID–based Lean Manufacturing’, Control and Decision Conference, Guilin, 17-19 June, pp. 5781-5784.

Yuan-Yuan Jiao., et al., 2008, ‘Hospital Linens Inventory Control Re-engineering Based on RFID’, IEEE Conference on Cybernetics and Intelligent Systems, Chengdu, 21-24 September, pp. 612-617.

Zang Li., et al., 2010, ‘Monitoring Object Motion Using Passive RFID Technology’, Program for the IEEE International Conference on RFID-Technology and Applications, Guanzhou, 17-19 June, pp. 233-238.

Reordering system still contain of a human activity which the worker need to remove the RFID kanban tag from the original place to RFID reading zone

Indicator light system is subjective to the environment lighting condition

The change of reorder level is limited by the fixed position of ultrasonic device
Recommendation and Further Improvement
To use the active RFID tag instead of passive tag, which it has a transmitter and its own power source.

Active RFID tag can triggered by the ultrasonic system, once the active tag activated the kanban signal is then could send to the reader automatically.

Design the track and adjustable bracket for the ultrasonic sensor,make use of DC motor to perform the adjustment

The user could adjust the reorder level easily by controlling the motor forward and backward through the graphical user interface.
Q & A
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