With thousands of racks moving between facilities and production stations, misplaced or stalled racks caused costly delays, inefficiencies and production bottlenecks.
The company needed a high-accuracy tracking solution to address two key challenges:
- Quality and Operations: Ensuring a seamless workflow required precise tracking of returnable containers with 99.9% data accuracy, reducing disruptions and lost assets.
- Ordering and Asset Visibility: Locating and managing thousands of racks across a massive production facility was a persistent issue. Limited visibility resulted in misplaced racks, slowed production and inefficiencies.
Without a scalable, automated tracking system, racks were often misplaced—resulting in missing parts, workflow interruptions or manual errors. This lack of visibility led to operational slowdowns, increased downtime, and unnecessary costs. The client turned to HID for a technology-driven solution to improve rack tracking, increase efficiency, and enhance real-time inventory accuracy.
The Solution: IQ On-Metal RFID Labels for Returnable Manufacturing Racks
HID worked closely with the client to implement a custom RFID solution, using IQOMLR1200 on-metal RFID labels to provide real-time tracking and visibility for their returnable racks. These durable, self-adhesive RAIN® UHF labels were designed specifically for on-metal surfaces—ensuring reliable performance in high-volume industrial environments. By integrating HID’s RFID labels with the client’s supply chain management system, they achieved the following:
Automated, Real-Time Tracking of rack movements throughout the facility
Elimination of Lost or Misplaced Racks, preventing workflow interruptions
Improved Production Scheduling, with insights into rack availability and transit status
Instant Alerts for Stalled Racks, reducing downtime and inefficiencies
HID’s RFID solution provided the client with a scalable and accurate tracking system—significantly improving operational efficiency and supply chain visibility.
HID’s RFID solution transformed how a top automotive supplier and supply chain OEM tracked and managed returnable racks, eliminating inefficiencies and ensuring smooth, uninterrupted production.
Lisa Moore, Sales Manager, U.S.A.
The Benefits of RFID Tracking for Returnable Manufacturing Racks
By implementing HID’s RFID technology, the company has revolutionized the way it tracks, controls and manages its manufacturing racks.
- Eliminated Misplaced Racks – With real-time visibility, lost or forgotten racks were no longer an issue, ensuring parts moved through production without delay
- Accelerated Production Speed – Automated tracking allowed for faster decision-making, reducing downtime and optimizing rack rotation
- Lowered Operational Costs – By eliminating manual searches and barcode scanning, the workforce could focus on higher-value tasks
- Optimized Asset Utilization – RFID-enabled predictive maintenance helped prevent overuse or unnecessary asset replacement
- Enhanced Supply Chain Transparency – With real-time tracking data, the client could make informed, proactive decisions to meet production demands more efficiently
With HID’s expertise in RFID technology, the client gained a competitive advantage—achieving seamless operations, increased productivity and full supply chain visibility across all manufacturing sites.
