Technical Proposal: RFID and Zebra
Receiver-based Warehouse Inventory
Management System using FIFO with
Active and Passive Tags for Location
Tracking
1. Introduction
Efficient warehouse management is crucial to ensure proper stock rotation, prevent stock
obsolescence, and improve operational efficiency. By using RFID (Radio Frequency
Identification) technology in conjunction with Zebra RFID receivers and combining both
active and passive RFID tags, the system can provide precise tracking of inventory and
locate items down to specific racks and bins. This ensures real-time visibility into the
inventory’s exact location, enhances the FIFO (First-In-First-Out) principle, and reduces
errors in picking, packing, and dispatching products.
2. Objectives
- Implement an RFID system for automatic tracking of warehouse inventory, using both
active and passive RFID tags to ensure real-time product location visibility.
- Ensure proper product rotation using FIFO principles.
- Utilize Zebra RFID receivers to capture item movement and exact location within the
warehouse, down to the rack or bin level.
- Improve warehouse efficiency and minimize human error in tracking, picking, and
dispatching items.
3. System Architecture
3.1 RFID Technology Overview
- RFID Tags: Both passive and active RFID tags will be used. Passive UHF RFID tags will be
attached to individual items, while active RFID tags will be used to track racks, bins, and
larger assets in the warehouse. Active tags provide continuous location updates, while
passive tags are scanned upon proximity to RFID readers.
- Zebra RFID Receivers: Fixed RFID readers (e.g., Zebra FX9600) will be strategically
installed across warehouse entry/exit points, racks, and other high-traffic areas, while
Zebra handheld RFID readers (e.g., MC3300) will assist workers in scanning and locating
items manually.
3.2 Key Components
- Passive RFID Tags: UHF passive tags will be applied to individual products, cartons, or
pallets, providing a cost-effective solution for item-level tracking.
- Active RFID Tags: Used to track the location of racks, bins, or large assets, providing
continuous real-time location data for warehouse assets and high-value items.
- Zebra RFID Receivers: A combination of fixed readers (for continuous scanning of tagged
assets and products) and handheld readers (for manual scanning by warehouse staff) will
provide flexibility in data capture and ensure precise tracking.
- Middleware and Warehouse Management System (WMS): Middleware will process RFID
data, enforce FIFO principles, and update the WMS with real-time inventory levels and
location data.
4. Workflow
4.1 FIFO-Based Warehouse Management
The system ensures that products are rotated in FIFO order, while active RFID tags enable
precise location tracking of racks and bins:
- Receiving Products: Upon arrival, RFID tags (both active and passive) are scanned, and
their locations are logged in the system.
- Storage: Products are placed in racks or bins, with active RFID tags providing the exact
location within the warehouse. Passive tags on individual items will store the product’s
unique identification and other necessary information.
- Picking and Dispatch: When an order is placed, the system will direct workers to the exact
location of the oldest items based on FIFO principles. The Zebra handheld RFID reader will
assist workers in locating the correct rack and bin, ensuring the correct items are picked.
4.2 Real-Time Product and Location Tracking
- Tagging: Passive RFID tags are attached to every product or carton, while active RFID tags
are affixed to racks, shelves, and large assets.
- Location Tracking: Active RFID tags continuously transmit their location, enabling the
system to provide real-time rack and bin location data. Passive RFID tags are read by Zebra
handheld readers when items are picked or scanned during inventory checks.
- Location Alerts: If an item is misplaced or stored in the wrong location, the system can
alert warehouse staff to correct the error, enhancing inventory accuracy.
5. Detailed System Components
5.1 Passive RFID Tags
- UHF passive RFID tags are affixed to individual products or cartons.
- These tags can be read from distances of 1 to 12 meters, depending on the warehouse
layout.
5.2 Active RFID Tags
- Active RFID tags are used on racks, shelves, and high-value assets to continuously
broadcast their location.
- Active tags have a longer read range (up to 100 meters) and provide real-time location
data.
5.3 Zebra RFID Receivers
- Fixed RFID Readers (e.g., FX9600): Installed at key warehouse entry/exit points and along
aisles to continuously monitor the movement of both active and passive RFID tags.
- Mobile RFID Readers (e.g., MC3300): Used by warehouse staff to manually scan products
and assist in locating items based on FIFO order and real-time location data from active
tags.
5.4 Middleware and WMS
- Middleware: Responsible for processing RFID data and integrating it with the WMS. It
filters and sorts RFID data, ensuring that both active and passive tag information is
correctly logged in the WMS.
- Warehouse Management System: The WMS stores all product information, inventory
levels, and location data. The integration of RFID with the WMS ensures real-time updates
of inventory and location data, making it easier to track products and follow FIFO principles.
6. Key Functionalities
- Automated Inventory and Location Tracking: Both passive and active RFID tags enable
continuous tracking of inventory levels and precise product location within the warehouse.
- FIFO Stock Rotation: The WMS ensures that the oldest stock is picked first using FIFO
principles. The Zebra handheld RFID readers guide workers to the correct rack and bin for
the oldest stock.
- Real-Time Location Assistance: Active RFID tags provide the exact location of racks and
bins. When an item needs to be picked, the system can direct workers to the exact aisle,
rack, and bin location using Zebra handheld devices.
7. Team Members and Roles
7.1 Project Manager
- Role: Oversees the entire project, ensuring alignment with goals and deadlines.
- Responsibilities: Coordinates between technical teams, warehouse staff, and management;
manages timelines, budgets, and resource allocation; and oversees system testing and
deployment.
7.2 RFID System Architect
- Role: Designs and oversees the technical implementation of the RFID system.
- Responsibilities: Works on designing the RFID network architecture, selecting the right
combination of active and passive tags, and ensuring optimal reader placement for
complete warehouse coverage.
7.3 Middleware/Software Engineer
- Role: Responsible for the development and integration of the RFID middleware and WMS.
- Responsibilities: Develops middleware that processes RFID data, ensures seamless
integration with the WMS, and ensures that FIFO logic is applied within the system.
7.4 Warehouse Operations Lead
- Role: Manages the warehouse operations and integration of the RFID system with daily
processes.
- Responsibilities: Works with warehouse staff to ensure they understand the RFID system,
leads training sessions, and ensures compliance with new operational workflows.
7.5 RFID Field Technician
- Role: Handles the physical deployment of RFID hardware, including tags, readers, and
Zebra handheld devices.
- Responsibilities: Installs RFID readers, applies tags to racks and products, tests system
performance, and troubleshoots technical issues during the implementation phase.
7.6 Data Analyst
- Role: Analyzes data collected from the RFID system to improve warehouse operations.
- Responsibilities: Provides insights on inventory movement, stock levels, and usage
patterns; ensures FIFO compliance; and helps optimize warehouse space and operations.
7.7 IT Security Specialist
- Role: Ensures the security and privacy of RFID data.
- Responsibilities: Implements encryption and access control measures, monitors for
security breaches, and ensures data compliance with industry regulations.
