RFID-Enabled Trolley Tracking for Streamlined Material Flow and Enhanced Traceability

Inventory management is central to efficient management systems for increased productivity and tracking of resources. Industry 4.0 (I4.0) revolutionises the manufacturing sector by integrating advanced digital technologies like the Internet of Things (IoT), leading to smart factories with enhanced efficiency and flexibility. Inventory management compliments this transformation, particularly if it includes tracking technology and Visual Management Systems (VMS), which convert tracking data into actionable insights, optimising processes and reducing waste. This paper presents a novel application of Radio Frequency Identification (RFID) tracking technology in conjunction with a Business Intelligence (BI) VMS for tracking inventory trolleys within a large-scale aerospace manufacturing environment. An RFID-VMS system including passive RFID cards, a USB hub for remote connection and a Power BI VMS were implemented providing intuitive key performance indicator (KPI) visuals, mobile accessibility and increased production line efficiency by 45%. Missed takt times decreased by 52.2% and line stops decreased by 75% indicating substantial improvements in maintaining the production schedule and reducing interruptions. The prototype implementation cost $600 covering RFID hardware, software, and infrastructure updates. Scaling to a full production line would require an estimated investment of $36,000 with a projected annual waste cost reduction of approximately $2.45 million. The number of blue cards increased by 7.9% reflecting an increase in throughput and production efficiency. As a result, the system supports sustainability by reducing operational waste and optimising inventory management, aligning with UN Sustainable Development Goals (9: Industry, Innovation, and Infrastructure and 12: Responsible Consumption and Production) and promoting economic growth. This simple, yet effective system framework could be applied to a number of sectors where materials must be tracked and recorded into and out of different locations at different intervals.