RFID for Oil and Gas

T.S.Rangarajan (ts.rangarajan@tcs.com)
Head, RFID Solutions
Tata Consultancy Services Ltd. (http://www.tcs.com/rfid)

Tata Consultancy Services ltd.

7 June 2006

Agenda
What is RFID and how does it work?
RFID Tags and their classification
RFID readers
RFID Middleware
RFID applications and value chain
TCS in RFID
RFID case profiles from TCS
Detailed case study Virgin Atlantic
Questions from Petrofed members
2

What is RFID and how does it work?

RFID identifies individual items
y Aircraft assemblies
y Aircraft sub assemblies
y Aircraft components
RFID tags consist of
y Integrated chip
y Integrated antenna
y Varieties: Passive tags, active tags with (battery) power source, etc
RFID readers can read many tags
y Line of sight not required
y Anti-collision prevents interference
RFID readers may be
y Handheld or stationary
RFID equipment has its own allotted frequency band

RFID - a birds eye view

n Reader broadcasts
signal through antenna
Antenna

reads the data

q Antenna
rReader sends data/info to
and sends to reader
computer for processing
Reader

sComputer sends event based

data to be stored on tag
pThe Charged tag sends identifying
response back to the reader

RFID
Middleware

Enterprise
Applications

Polyethylene Media

Chip

receives signal
oTag
and gets charged

Tag
Copper coil antenna

Uses radio waves or micro waves for quick & automatic identification
Detection/data transfer is contact-less and doesnt need line of sight
Tags can store data and help maintain historical information

RFID tags

125 kHz

13.56 MHz

UHF 902-928 MHz

2.45 GHz
5

Classification of RFID tags

RFID tags and their frequencies

Read range 2 meters
Low ( 125-134 kHz)
Great penetration
Slow data rate
Costlier tag antennas
Multiple tags cannot be read together
Read range 1 meter
High Frequency (13.56 Good penetration
MHz)
Simultaneous read capability @ 50 tags
Most progress on standard setting
Read range 10 meters.
UHF (868, 902-928 MHz) Fast data rate
Simultaneous read capability @ 50 tags
2.45 GHz

Read range 1 meter

Very fast data rate

Spectrum use is often regulated by governments (13.56MHz designated for ISM applications
in most countries)
UHF frequencies (850 - 960 MHz) for RFID vary from country to country
Read range is greater with battery powered tags (active/semi passive)

RFID readers
Basic readers
y Provide serial port interface
y Host initiated Request-Response protocol
y Basic commands includes reading a block, writing a block and locking

Advanced readers
y
y
y
y
y
y
y
y

Provide serial and ethernet interface

TCP/IP stack included - provide Telnet and http interface
Provide command line and web interface
Advanced command set
Provide advanced digital inputs and outputs
Autonomous mode - response on user defined triggers
Heartbeat messages
Advanced outputs formats - text, XML

RFID readers and antennae

Readability and range depend upon the design of readers and antennae
9

RFID middleware
RFID Data Characteristics
y High Volume - some applications may have > 100,000 readers generating
terabytes of data
y Fast rate - several reads / second
y Multiple redundant reads of same tag data
y Reader health monitoring and management

RFID Middleware
y Connects data from RFID readers to Enterprise applications
y Device monitoring and management

Middleware features
y
y
y
y
y

Device driver / control, diagnostics, remote maintenance, upgrades

Data aggregation
Data filtering and smoothing
Event monitoring
Connectivity

10

RFID applications and value chain

Healthcare

Manufacturing
Supply chain
management &
distribution
Production
management
Factory
Automation
Maintenance /
condition
monitoring
Asset
management

Asset Tracking
Patient tracking
Personnel tracking
Sterile Equipment
management
Blood bags
tracking
Anti counterfeiting
of pharmaceutical
products
Medicine
dispensing

Chips

Inlays

Tags

Silicon companies TI,

Philips , Siemens, Hitachi
Tag manufacturers
EMS, TI, Matrics, Alien

Antenna

Transportation

Retail

Telecom

Airlines
baggage
handling
Boarding pass
Package
Tracking
Container
Tracking
Yard
Management
Toll collection
Fleet tracking
Rail car ID

Inventory
management
Warehouse
operation
Supply Chain
Management
Interactive Kiosk
Self check out at
POS
Electronic Article
Surveillance

Asset Tracking
and Management
Contact less
Payment solutions
using mobile
phones
Billing solutions
Various Value
Added Services

Reader
Reader
Network

Middle
ware

RFID Reader / Antenna makers EMS, TI,

Matrics, Alien, Hitachi
RFID Software providers OAT, Sun,
ORACLE, SAP, Globeranger, Matrics,
ConnecTerra Savi

11

Systems
Integration

EAI

Analytics/
Process
Redesign

IT Solutions & Services providers

Tata Consultancy Services
Accenture, IBM GS, CGEY
Wipro

Differentiation by synergy
RFID expertise & Assets
RFID Lab since 2001
RFID Center in Chicago
Presence in Oracle Sensorworld,
UK
Hardware & middleware expertise
Tools & assets
Member of

RFID Technology
expertise

Strategic alliances
Oracle
Texas Instruments
Hitachi
Sun Microsystems
EMS

TCS RFID
Solutions

Domain
experience

Technology
expertise
Hospital Management system
Architecture
ERP / SCM / WMS
Application development
Application integration (EAI)
Business Intelligence & DWH

Pharmaceuticals & Healthcare

Transportation & Logistics
Retail & CPG
Manufacturing
Government
Utilities
12

TCS RFID Stack

Process consulting
Data and event utilization
Strategy & Business case develop
EPC / GTIN consulting

Business
Business Processes
Processes

Enterprise
Enterprise Applications
Applications

Application
Application // Integration
Integration
Servers
Servers

Application Development
Custom Modifications

MIDDLEWARE
Reader Interfaces, Reader Adapters,
Filters and logger, Reader management
RFID integration with EAI

Edge
Edge Processing
Processing Layer
Layer

Hardware
Hardware Interface
Interface
Layer
Layer
Site Surveys
Reader and Tag Selection
RF Engineering,
Antenna placement & design ,

RFID
RFID Hardware
Hardware

13

TCS RFID expertise centers

Objectives

Details

Sensor World,
UK

Ability to run pilots and test full scale implementation

projects with our customers.
Presentation and demonstration facility for TCSOracle RFID solutions
To enable business mangers to see tangible
evidence of the potential of RFID technologies to
deliver business value

Running real life scenarios for:

Asset Management Zone
Customer Experience Zone
Supply Chain Zone
Product Zone
Management Zone

RFID
Technology
Center, Chicago

Demonstration and piloting of solutions in numerous

industry segments
Access to leading RFID tech
Performance testing, analysis and benchmarking of
RFID hardware and middleware products.
Facilitate end-to-end integration testing

Readers, antennas and tags: HF and UHF

Middleware from Sun, Oracle
Site Simulation Facility for Dock doors, smart shelf,
conveyors

Demonstrate industry specific RFID applications.

RFID physics related testing: Product evaluation and
benchmarking.
Integrate RFID hardware and middleware

Established in 2001; approx. 20 researchers

Hardware: HF, UHF and MW from TI, EMS, Hitachi
and Alien
Middleware: Sun, Oracle and Auto-Id Center
Antenna footprint Analysis, Power Spectrum analysis,
Tag placement and readability tests

RFID Center of
Excellence
Kolkata

14

Enhancing airline MRO Operations

Client:
Scope
y High value rotable parts at Heathrow warehouse
y Integration with Enterprise MRO application
Objectives
y To improve performance and reduce cost
y To improve the visibility of critical parts
y To provide clear measurement of the impact of the pilot
y To improve the service provided by the warehouse
Benefits
y Reduction of cost of labor associated with managing goods/business processes
y Improve visibility into the incremental steps that are part of complex business
processes
y Improve visibility into customer (Internal and External) demand
y Better forecasting
y Enhanced product visibility in the stores
y Eliminating the possibility of misplacement of high value assets
y Automatic recording of items entry and exit from the storage area
y Reduction of manual errors in data recording & data entry

15

Case Study

Engagement with a leading CRO

Scope:
y Specimen receipt management from investigator sites
Courier
During
y Sample management
Pickup
Transportation
Mode
Accessioning,
Packaging
y RFID tagged Tubes
Routing,
Kit Samples
Aliquoting
Pain points addressed
Sample
Lab Testing
y Lack of end-to-end visibility for sponsor
Draw
and Results
y Long trial times for sponsor
Visit
Package
y Long lead-times for patients
Scheduling
Reception
Expected benefits:
y Error Reduction at Investigator site
y Reduction in shipment and stability related issues
y Reduction in data management issues (automatic
scanning)
y Chain of custody and effort reduction within central labs
y Advanced Capacity planning/forecasting and allocation
Increased stakeholder Satisfaction
Unique ID linked
y Reduced loss of data points for clients
to back end system
y Reduced re-testing with patients (human aspect)
for automated Kit
production line
16

RFID enabled product authentication scenario: a

prototype
Technology
y Microwave RFID tags
y Handheld readers

Data
cable

y Web based authentication application

Features

Plastic
Nose

y Extremely small size of product

y Tag is injection molded into product
y Handheld RFID reader used for reads
y Tags commissioned and ids are registered in database
y Central authentication server
y Thin authentication client
y Web service based communication

Metallic
part

TI Reader
Authentication client

Benefits

TI Reader
Oracle 10g server

y Impossible to duplicate product ids

Authentication client

y Counterfeits can be easily detected

y No other technology allows embedded ids

TI Reader

y Flexible and scalable architecture

Authentication client

17

Product authentication server

Windows 2000 server
Oracle server

RFID based inventory management for Kansas DOT

Client: Department of transportation, Kansas state, US of America
Scope: Identify how RFID can provide an optimum level of information for
y Capital Inventory tracking
These assets are dispersed over the entire State of Kansas and their value is $307,057,000+.
The number of physical locations of the Capital Inventory is approximately 28 headquarters offices
in Topeka and 159 statewide field offices
y Consumable Inventory tracking
KDOT manages between $12 and $15 million in consumable inventory at any given time.
There are 41 manned stock locations and approximately 420 unmanned locations statewide
y Materials Testing
Deliverables:
y Study Report
Impact on existing databases and applications
Impact on existing processes
Analysis of costs and benefits
Suggested roadmap
y Technology Recommendation Report
Includes hardware and software required for interfacing RFID system
Details of suitable RFID tags and readers
Middleware required
Network requirement

18

RFID based inventory management

Client: A leading medical equipment manufacturer.
Pain Areas
y Inaccurate inventory records
y Data inconsistencies between the ERP and actual bin level
status
y Every month, 2-3 days production is lost for cycle counting
Solution
y Manual bin cards replaced by re-writeable RFID tags
y Reader applications developed to reduce errors
y Data integration was done with the ERP
Benefits
y Instant visibility of stock due to real-time updation
y Elimination of error due to manual entry
y Automatic checking of parts being picked
y Cycle counting eliminated
Technology
y Passive tags HF tags on Warehouse bins
y Handheld reader
y Integration with Oracle Apps

19

RFID based document tracking

Client
y Indian defense division
Scope
y Document and file tracking
Features
y Handheld RFID reader integrated to PDA
y Automated document inventory and tracking application
y Synchronized with desktop document management
application
y Document issue history available in document itself
Benefits
y Improved document inventory visibility
y Reduction in misplaced documents
y Reduced effort in tracking classified documents
Technology
y High Frequency RFID tags from TI
y Handheld RFID reader

20

RFID based car tracking

Client
y A leading auto auction house, US
Pain Areas
y Difficulty in locating individual cars in an area spread across 80 acres
y Manual identification and tracking process extremely time consuming, error prone
y Mandatory verification of buyer ID and vehicle ID at exit cumbersome
Solution
y RFID tags fitted to each vehicle
y Identify and track vehicles at entry, parking lot, detail shop, run lines and exit
y Integration with existing auctioning application
y Metrics collection on vehicle sales and cycle times
y Status reports and dashboard
y Verification of buyer id and vehicle Id at exit
Technology
y Active tags on vehicles to be identified and tracked
y Fixed and Handheld readers
Benefits
y Ensure complete up to date inventory
y Replace labor intensive bar code system
y Automatic billing
y Enhanced security
y Market intelligence
21

RFID based asset management

Client:
y A premier Electrical equipment manufacturer
Scope:
y Asset and equipment tracking at power plants
Technology
y Passive tags on equipment /asset to be tracked and maintained
y Active tags in case assets may move over a wide area
y Gate and Handheld readers
Features
y Identify location of equipment / assets
y Asset / Equipment identifies itself
y Data storage capabilities - update equipment history on tag
y Handheld displays equipment details to field worker
y Automatic upload of field data to servers after field work is completed
y Integration with Asset Management application ( Oracle database)
Benefits
y Accurate identification
y Superior performance in harsh environment
y Local data storage and availability without need of data networks
y Reduced workload and increase in efficiency

22

RFID Reader

RFID based quality system for tobacco

RFID based management of quality tests on tobacco
samples in a cigarette factory
Objectives
y Reduce time required for testing lab samples
y Reduction of manual effort in data recording & data
entry
y Reduce data entry errors
Features
y Identification and Tracking of tobacco samples
y Automatic data capture at sample collection site and
laboratory
y RFID tags metallic tobacco containers
y Specially designed tags to withstand high
temperature cycles
y Integration of RFID reader with weigh scales
y Automated capture of tag id and weight from
weighing scale
y Data logging to QMS database
y Reports and query support

RFID Based Tobacco Quality

Technology
y Passive HF Tags ( TI)
y HF Fixed Reader ( Custom designed)
y Handheld Readers ( Psion Teklogix)
Management
y MySQL database
y .Net application

23

RFID based lorry tracking inside a refinery

Salient Features of Lorry tracking System Application
Zonal tracking of lorries inside the facility
Application developed on MS DOTNET platform
Integrated with photo-pass system
Integration with SAP ERP
Accessible through Mobile platform
Scope of work

Hardware:
y Procurement from NEDAP, Netherlands
y Installation at site
y Testing and system configuration
Application development:
y Requirements gathering and SRS preparation
y Software development
Integration:
y Interfacing various hardware components like RFID, photo
pass camera, etc,
y Providing an interface for integration with SAP systems at
multiple instances
Support:
y Training and implementation support

24

Benefits
Higher customer satisfaction: as real-time status of the location of the
lorry will be communicated to the owner of the lorry as well as the
consignee.
Better queue management: as the information of the movement of
traffic is available at the entry point.
Responsiveness: of the system to manage any changes in the filling
order
Reduction in administrative effort
Arresting discrepancies in scheduled orders

RFID based body shell tracking in automobile paint shop

Body shell tracking in an automobile paint shop
Technology
y Low Frequency ( 134 KHz) RFID tags from TI
y High temperature tags capable of withstanding 350
deg C
y Fixed RFID reader
Features

y RFID tags used for identifying and tracking body

parts in paint shop
y Fixed RFID readers placed at 7 locations in
paint shop
y Tags placed on skids that carry the body shell
y Readers integrated with plant automation
system ( PLC)
y Body Serial number, colour code, model
description code etc. is associated with RFID
tag and used at different locations

25

Benefits

y Automated identification of body shell

y Decentralized control of manufacturing
based on RFID tag

Virgin Atlantic and RFID

What are the expected benefits of using RFID
technologies?
4Process efficiencies Data capture;Data accuracy
4Improved turn around performance of components through stores.
4Increased visibility of parts and materials within the maintenance
environment
4More accurate inventory control at the point of entry to the aircraft
stores
4Consequential benefits process control
In addition to these benefits, the wider benefits include:

4Greater ability to comply with expected guidelines from EASA

(European Aviation Safety Agency) concerning traceability and
authenticity of aircraft components
4Integration with the RFID specifications proposed by Boeing and
Airbus for use within the aircraft supply chain

26

The Pilot Study

The high level scope of the pilot was:

4To RFID tag all rotable parts within the Heathrow warehouse
4To integrate with Ultramain process
4To provide automated tag printing to work in line with existing Goods inwards
process

The objectives of the pilot were:

4To demonstrate the potential savings of using RFID tags

4To improve the visibility of critical parts
4To provide clear measurement of the impact of the pilot
4To improve the service provided by the warehouse
4To test the technology

27

The Pilot Study - architecture

P re s e n ta tio n la y e r

M id d le w a re la y e r

D a ta la y e r

K P I in te rfa c e A p p lic a tio n

E d g e A p p lic a tio n

D a ta h u b
K P I A n a ly s is
E d g e S e rv e r

R e a d e r S e rv e r

D a ta h u b in te rfa c e

U ltra m a in In te rfa c e

P rin te r In te rfa c e

28

Pilot Environment
Quarantine

Wireless
network

Back Office

Inspection

First Stage

Printer

Bins
Binning
Area

Handheld

RFID
Label

Component
Repair Section /
Dispatch

Bulk Racking

Preload / Bulk
Deferred Defect

Location
Barcode

Back Office

29

KPI measurement
4Each stage of process
is measured
Average times
Data accuracy
compare Ultramain with
data hub
Identify supply
blockages
Identify fast track
items
Item life cycle

30

Questions from responses

LPG Cylinder tracking cost, availability
Oil Tanker tracking
Document tracking
Asset tracking
Access control
Oil retail outlets
Handsfree RFID based payments at pumps
Tag life cycle management
Safety in inplant use?
Hazardous use
Reading accuracy and inteference
Integration with backend
Preventing adulteration and pilferage
31

32