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Success story

ABB

Material tagging helps with factory automation and plays a part in increasing the factory throughput with 60%.

ABB, a globally leading power electronics and automation company, embarked on an ambitious automation initiative at its Breakers and Switches factory in Vaasa, Finland. By implementing RFID, they achieved seamless automated material flow, leading to a remarkable 60% increase in factory throughput.

RFID Expert Tomi Lundström

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Tomi Lundström

Business Development Manager

Challenge

Boosting Productivity Through Automation

In 2011, ABB’s Breakers and Switches factory in Vaasa, Finland aimed to significantly increase its productivity. As a key manufacturing site, representing 80% of all ABB products in its category, the management set a critical initiative to enhance factory output. This required a comprehensive automation plan that integrated all aspects of material handling, from inbound logistics to outbound delivery, to ensure smooth production and achieve ambitious throughput goals.

When a truck pulls in to deliver goods for the factory, the RFID system registers items in the delivery directly to the company’s SAP offering instant availability information.

Benefits

Major Productivity Increase

Seamless Material Flow

Instant Material Availability

Enhanced Employee Satisfaction

Outcome

The factory is now nearly fully automated, integrating RFID with 20+ robots and automated forklift trucks. This comprehensive automation has led to a 60% increase in factory productivity and growing volumes. Beyond these gains, the reduction of manual tasks by RFID significantly improved employee satisfaction, reducing sick calls and allowing personnel to shift to higher-value roles.

Solution

RFID as the Core of Automated Material Flow

ABB implemented an RFID-based solution as a key element in its factory-wide automation strategy, driving automated material flow throughout:

  • RFID-Enabled Inbound Logistics: RFID readers automatically register incoming delivery items directly into ABB’s SAP system as trucks arrive at the factory. This provides instant availability information for all incoming materials.
  • Automated Outbound Logistics: Each handling unit for customer orders is monitored with RFID. After paperwork is finalized in SAP, units are moved to the outbound freight area and loaded onto delivery trucks, with RFID monitoring and verifying the loading process to ensure it is error-free.
  • Seamless Material Integration: RFID seamlessly connects and optimizes material flow within the factory’s highly automated ecosystem, which also includes 20+ robots and automated forklift trucks.

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