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Batch size 1 production

Efficient control – without paper

RFID and digital systems allow you to maintain an overview even with a wide range of variants and individual customer requirements. Manage production and material flow flexibly, reduce setup times, and lower error rates.

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Why batch size 1 production poses special challenges

Batch size 1 production


Traditional production processes are optimized for large quantities. With batch size 1, they reach their limits:

Hohe Setup and changeover times through manual settings

Low transparency about order status and material availability

Frequent rescheduling due to individual customer requirements

Risk of errors due to manual data entry

Push principle leads to Overproduction and storage costs

What digital systems do better


Digital solutions enable flexible and transparent manufacturing even with a high degree of variant diversity:

real-time data throughout all process steps

Automated identification of products, tools, and materials

Series, batch, and quality documentation

Visualization and worker guidance right at the workplace

Pull principle: Only what is needed is produced

Traditional vs. RFID-supported manufacturing in batch size 1

Criterion

Traditional manufacturing

RFID-supported manufacturing

Lead times

Long turnaround times due to manual coordination, waiting times, and lack of transparency.

Short turnaround times thanks to automated identification, real-time data, and optimized material flow.

Error rates

High error rates – caused by manual entries, lack of traceability, and communication errors.

Low error rates – Automatic data capture reduces input errors and mix-ups.

Setup times

Long setup times – Result from frequent changeovers and manual adjustments.

Short setup times – Automatic product recognition enables quick adjustment.

Material flow

Uncoordinated material flow – due to production for stock (push principle) and high inventory levels

Optimized material flow – based on the pull principle, just-in-time through real-time tracking

Advantages of RFID-supported manufacturing in batch size 1

[Translate to English:] Zeitersparnis
Shorter turnaround times

Machines and employees always know where each product is and what happens next.

[Translate to English:] Geringere Fehlerquoten
Lower error rates

through unique identification and automated data collection

[Translate to English:] Automatisierung
Reduced setup times

thanks to automatic adjustment of machine parameters

[Translate to English:] Transparenz
Transparent material flow

through seamless location and status tracking

Challenges in batch size 1 manufacturing – and how RFID helps

1. Complex planning

Individual orders require precise sequencing and material feeding. RFID ensures automatic recognition and planning in real time.

 

2. Variety of options and documentation

Each variant requires its own work steps and materials. RFID tags document serial numbers, batches, and parameters directly in the process.

3. Production optimization for dynamic processes

No two orders are alike. RFID-supported systems provide real-time data to monitor cycle times and continuously optimize processes.

4. Worker guidance and machine control

Workstations receive product-specific information directly from the system. Machines automatically adjust to the product.

5. Quality assurance at component level

All manufacturing steps and quality characteristics are clearly assigned. This enables each individual part to be evaluated and provides data for optimization.

Our solution in practice: VELUX

VELUX manufactures a wide variety of roof windows in batch size 1 on a single line. Control is achieved with the help of digital worker guidance—completely paperless:

  • Machine and system connection
  • Digital display of work plans and instructions
  • User-specific provision of instructions in stored languages
  • Pick-by-light system for safe material removal
  • Real-time monitoring of cycle times for more precise production planning

Today's traceability solution ruthlessly exposes deviations in cycle times and enables targeted optimization of processes by using automatically collected data on individual parts to identify the product groups or specific product types that are causing cycle time overruns on the assembly line.

Over the past two years, we have switched our production from pure mass production to single-item manufacturing ... Production documents are no longer usable in this environment. With RFID technology and SIGMA as a competent partner, we have found a technology that meets our requirements in this area and which we will roll out in other production areas over the next few years.

Toralf Brandt
Production manager JTJ Sonneborn Industrie GmbH

VELUX

Our approach

[Translate to English:] SIGMA

We support companies in implementing efficient, digital batch size 1 manufacturing. We take all requirements into account—from identification and machine connection to worker guidance.

Your benefits:

  • Fewer errors
  • Shorter setup times
  • Transparent material flow
  • Data-based decisions
  • Future-proof production even with increasing variant diversity
Talk to us!

We will be happy to present solutions for your industry and your processes. Talk to the specialists for SMEs.

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Contact person
Viktor Wagner
Viktor WagnerManaging Director

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