How This High-Tech Leader In Building Materials Adds Real-Time WIP Visibility To Its Manufacturing

Updated: Nov 10, 2020

The company, which has asked to remain unnamed, sees an opportunity to build a significant competitive advantage in its production process.

Autoclave ovens at building materials manufacturer

The company is a world leader in building materials, operating around the world. It is well known for its finished cement boards, a high-tech mix of cement and fibers. The company’s US-based Project Manager responsible for selecting and deploying the solution across their 8 North-American plants shared an update about the project.

Challenges Looking For Solutions

In order for the solution to be successful, four specific challenges have to be addressed:

  1. Substantial losses occur throughout the production process: How to develop Work-In-Process visibility from raw material to finished products in order to keep track of everything?

  2. Most products come with paper labels that don’t stick well: How to avoid wasting so much time walking around products to find and read identifiers?

  3. Our cement boards are cast into molds and baked in an autoclave, where all RFID tags failed: Is there a solution that withstands high temperatures, for how many hours, and at what pressure?

  4. Our manufacturing environment is very dusty and busy: Would RFID be able to have a read without having to move everything?

On The Way To Scaling-Up

The company found a number of promising options in the market that could meet their requirements for an RFID tag to be mounted onto the cement board molds and survive autoclave temperatures. The products selected were then put through a battery of tests designed to replicate the company’s demanding manufacturing environment.

And in the end, it is the Xerafy Roswell Autoclave RFID Tag that came out on top, ranking highest when it comes to high temperatures and pressure, shock resistance, accuracy and read range, wide read angle, as well as reliable mounting options.

The company has now decided to go ahead with its next phase, with extensive tests in the field, in order to finalize how best to track the molds, capture information throughout the production process, and eventually scale up the solution to all their production sites.