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Traceability
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Improved delivery reliability: Recognize and eliminate delivery bottlenecks at an early stage.
Reduce search times: Gain complete transparency about the time and location of orders, containers or material.
Efficient complaint management: Facilitate the processing of complaints through the precise traceability of materials and products.
Reduction of production errors: Minimize production errors to ensure the quality of your products.
What our customers say
By implementing the GRAIDWARE® Track and Trace system, we have complete control and transparency over our production process. The system enables us to track every step in the manufacturing process of safety-relevant body parts and also to continuously optimize quality and efficiency. The stored data opens up enormous potential for us, not only in terms of improving quality, but also for future developments and innovations in our production.
Marc Schweizer, Business Development Manager
Business Development Manager
Thanks to SIGMA's RFID solution, KWS is now able to uniquely identify each seed bag and track its path from filling, storage and delivery to the customer. The centralized data storage forms the basis for comprehensive reporting.
Tobias Scharffetter, Head of Marketing Corn & Sunflower Europe/Asia
Head of Marketing Corn & Sunflower Europe/Asia
What is traceability?
Traceability refers to the ability to track the entire life cycle of a product - from the procurement of raw materials through production to delivery and disposal - without any gaps. This makes it possible to trace when, where and by whom a product was manufactured at any time.
Traceability plays a decisive role in production and logistics. It ensures transparency along the entire value chain, improves quality control and makes it easier to identify and rectify errors. By recording and managing relevant information, companies can react quickly to quality problems and carry out targeted recalls.
An effective traceability system requires the implementation of appropriate labeling and data capture technologies, such as RFID tags, barcodes or QR codes. This data is stored and processed in manufacturing execution systems (MES) to ensure complete documentation.
Why you should introduce a traceability system
A well thought-out traceability system does far more than just provide traceability - it becomes a strategic lever for efficiency, quality and customer loyalty:
RFID technology enables automated recording and tracking of products, which leads to a significant increase in efficiency in the supply chain.
Practical example: By implementing an RFID solution, it is possible to monitor the condition of components that are manufactured in production.Potential problems are detected at an early stage and production times can be reduced in the long term.
Real-time monitoring allows companies to react immediately to changes and identify potential problems before they spread.
Practical example: Monitoring compliance with the cold chain for food is made possible with the help of sensors that record the ambient temperatures in cold storage rooms, transport vehicles and storage facilities.A warning is issued if temperatures fall outside the specified limit values.
RFID technology helps to improve the traceability of products by enabling companies to accurately document the entire product life cycle.
Practical example: Tracking medical instruments and devices makes it possible to document their sterility and usage history and thus comply with hygiene regulations.
Traceability enables companies to monitor the entire production process and ensure that products meet quality standards.
Practical example:In the electrical industry, the origin and condition of individual components are tracked.This is important for quality assurance and compliance with important regulations.
The implementation of a comprehensive traceability system in production offers an effective tool for tracking the production status without time-consuming research and reliably informing the customer about the delivery date. At the same time, the continuous monitoring of quality parameters enables compliance with the agreed delivery standards.
Practical example: Thanks to comprehensive traceability in the clothing industry, customers can track the entire supply chain of a product, from raw material extraction to production.This transparency creates trust and strengthens customer loyalty - because it is increasingly important to end consumers that products have been manufactured under fair conditions.
![[Translate to English:] Icon Fazit](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_fazit.svg "[Translate to English:] Fazit"){kind=icon}
A traceability system is not a “nice-to-have”, but a competitive advantage. It reduces risks, lowers costs and improves your process quality - measurably and sustainably.
Let us advise you - individually and without obligation.
Our solution for seamless traceability
We work with you in a dynamic and hands-on environment based on agile scrum methods to define the specific requirements and timelines of your production line. We develop customized track and trace solutions that enable the smooth coordination of processes in production and logistics.
Take advantage of our many years of expertise in the field of database-supported AutoID processes for tracking, visualization and documentation in the areas of production, logistics and supply chain. With our comprehensive solution, which integrates the latest technologies, you can achieve seamless traceability.
![[Translate to English:] RFID-Antenne](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_rfid-antenne.png "[Translate to English:] Icon RFID-Antenne"){kind=icon}
RFID reader and antennas
The central hardware for capturing RFID tags - supports various frequency ranges (e.g. HF or UHF) and enables precise reading.
Our readers are the heart of the track and trace system. They receive data from RFID tags attached to objects and send it to the central system. Depending on the location, we offer models with different reading ranges, protocol support and designs - for warehouses, production or shipping.
![[Translate to English:] RFID-Tag](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_rfid-tag.png "[Translate to English:] Icon RFID-Tag"){kind=icon}
RFID tags
RFID tags contain unique information for identifying objects and enable seamless traceability.
The selection of the right RFID tag depends heavily on the operating conditions - such as temperature, material, distance or movement dynamics. Whether low-cost labels or robust industrial transponders: we help you select the ideal tags for your processes and systems.
![[Translate to English:] WLAN](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_wlan.png "[Translate to English:] Icon WLAN"){kind=icon}
Network and communication equipment
For transferring RFID data to the system - via WLAN, Ethernet or other technologies.
The type of network infrastructure has a significant impact on the response time and stability of the traceability system. We advise you on the optimum connection technology depending on the environment - whether industrial environment, warehouse or outdoor use.
![[Translate to English:] RFID-Drucker](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_rfid-drucker.png "[Translate to English:] Icon RFID-Drucker"){kind=icon}
RFID printers
For creating individual RFID tags that can be attached directly to objects - for quick and clear identification.
RFID printers write and encode tags with all the necessary data - e.g. serial number, batch, production date. They can be seamlessly integrated into existing labeling processes and ensure secure, automated identification along the entire supply or production chain.
![[Translate to English:] Icon Middleware](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_middleware.png "[Translate to English:] Middleware"){kind=icon}
RFID middleware
Our RFID middleware GRAIDWARE® is the link between RFID hardware and ERP or warehouse management systems - for seamless integration of data flows.
Our GRAIDWARE middleware filters, validates and transfers RFID data to your business applications in real time. This avoids data disruptions and gives you maximum transparency about material flows and stock movements.
![[Translate to English:] Icon Datenbank](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_datenbank.png "[Translate to English:] Datenbank"){kind=icon}
Databases
Databases in the RFID ecosystem serve as a central storage location for information about RFID-tagged items.
Our database systems not only record movement data, but also metadata such as status, time stamps or user actions. This allows individual traceability rules to be set up - e.g. serial number tracking, batch management or automatic QA triggers in the event of deviations.
![[Translate to English:] Icon Handheld](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_handheld.png "[Translate to English:] Handheld"){kind=icon}
Mobile data capture
Capture RFID, 1D and 2D codes via scanner or handheld - directly at the point of use.
Whether incoming goods, stock transfer or production - with mobile recording devices, you can transfer data to the system decentrally and in real time. This allows you to remain flexible, react quickly to changes and increase process reliability along the entire supply chain.
![[Translate to English:] Icon Visualisierung](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_karten.png "[Translate to English:] Visualisierung"){kind=icon}
Visualization
Analysis and visualization of your recorded data - individually tailored to your processes.
The GRAIDWARE Center provides you with detailed evaluations of goods movements, inventories and traceability paths. The reports can be adapted to your key figures and targets - and help you to identify potential for process optimization.
![[Translate to English:] Icon Reporting](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_reports.png "[Translate to English:] Reporting"){kind=icon}
Reporting
Real-time overview of the locations of all objects equipped with RFID tags - with detailed maps and layouts.
Our visualization solutions provide you with a dynamic dashboard that shows you where each object is located at all times. Bottlenecks and irregularities are automatically highlighted so that you can react immediately.
Apps for mobile devices - flexible, location-independent & fully integrated
With our mobile applications, your employees always have an overview - regardless of location, device or workplace. The apps not only enable the identification of products and components, but also access to important additional information in real time.
Object recognition via scan directly on the mobile device
Access to assigned documents such as:
PDFs and manuals
Certificates & test documents
Production histories
Immediate display of all relevant process data
Direct documentation of defects via photo upload & comment function
Multi-level error categorization for subsequent Pareto analyses
Digital recording of rework (e.g. repairs, adjustments) - without losing order papers or design instructions
Notes and feedback will be:
digitally recorded (text or image)
automatically provided for subsequent workstations
No more lost order slips or outdated instructions
Information is always up-to-date and audit-proof
Our solution is not only powerful, but also modular and future-proof. It grows with your requirements - whether it's an individual production line or an entire logistics landscape.
Would you like to know how traceability can be implemented in your production?
![[Translate to English:] Traceability](/fileadmin/AutoID_RFID/rfid-tracking/traceability/lager_traceability.webp "[Translate to English:] Rückverfolgbarkeit im Lager")
Technologies used for comprehensive transparency
Achieve maximum transparency and efficiency in your supply chain by using the latest traceability technologies. The ideal identification methods must be evaluated in advance for the respective application. If necessary, our solution combines various powerful techniques to ensure seamless traceability with minimal effort for identification.
RTLS localization
The use of RTLS positioning technology enables the precise localization of moving objects such as trolleys, forklifts and vehicles in production and logistics environments.
The use of GPS tracking technology offers an effective way of tracking objects outdoors. By integrating with other identification technologies, effective solutions for outdoor tracking and tracing can also be developed.
HF transponders react to electromagnetic waves, but their reading range is often limited to a few centimetres due to the low frequency. Compared to other frequency ranges, their influence on interfering factors such as liquids and metals is rather low, which means that only individual transponders can be detected per reading process. They are often used to identify goods carriers in specific production processes.
UHF transponders can be activated contactlessly over a distance of several meters using electromagnetic waves and then identified. This allows them to be clearly assigned to specific production and logistics processes.
Barcode or 2D code labels continue to be used for the cost-effective identification of products and product carriers (UDI, batch, serial numbers, etc.). Efficient identification for traceability can be achieved if these labels can be automatically recognized in the production process by fixed camera solutions. Otherwise, a time-consuming manual scanning process is required.
If labels or RFID do not work due to heat, oil or dirt, the use of DMC is suitable. This enables the products to be visually identified at a later date.
Near Field Communication (NFC) technology is used for marking end products, among other things. Objects marked with NFC can be identified using both professional readers and modern smartphones, which ensures protection against counterfeiting. By uniquely labeling each product with an NFC tag, companies and consumers can verify the authenticity and origin of a product at any time.
Comparison of technologies used
Technology | RTLS | HF-RFID | UHF-RFID | GPS | DMC | Barcode | NFC |
Application | Indoor | Indoor | Indoor and outdoor | Primarily outdoor | Indoor | Indoor | Indoor |
Costs | High | Medium-high hardware and implementation costs, low operating costs | Medium-high hardware and implementation costs, low operating costs | High | Low | Low | Low |
Genauigkeit | Very high | High | High | Medium | Very high | Very high | High |
Informationsgehalt | Very high | High | High | Low | High | Low | Medium |
Reichweite | Very high | Medium (up to 1 meter) | High (up to 15 meters) | High | Low | Low | Low |
Automatisierungsgrad | Very high | High | High | Very high | Medium | Low | Medium |
The choice of the right technology depends on your specific application - we provide you with manufacturer-independent advice and find the ideal combination for maximum traceability and minimum process friction.
Traceability in production
What are the advantages of traceability solutions in production?
![[Translate to English:] Icon Rückrufaktionen](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_rueckrufaktionen.png "[Translate to English:] Rückrufaktionen"){kind=icon}
Root cause analysis and recall management: In the event of problems with products or batches, it is important to know which products were manufactured under similar conditions. Traceability enables a precise root cause analysis and the targeted blocking or recall of affected products.
![[Translate to English:] Icon CO2 Fußabdruck](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_co2_fussabdruck.svg "[Translate to English:] CO2 Fußabdruck"){kind=icon}
CO2 footprint: Traceability enables the recording and documentation of a component-related energy requirement and thus the basis for the verification of the emissions generated.
Quality control: Modern machines and systems provide process parameters via OPC UA. With the help of a digital traceability solution, it is possible to efficiently link individual production parts with time stamps and process parameters in order to draw conclusions about deviations in quality parameters. This makes it possible to achieve a permanent increase in quality.
![[Translate to English:] Icon Produktionsleistung](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_produktionsleistung.svg "[Translate to English:] Produktionsleistung"){kind=icon}
Optimized production performance: To evaluate and optimize production performance, the SIGMA Track and Trace solution offers an evaluation of overall equipment effectiveness (OEE). The visualization at various terminals shows the status of production orders and helps your employees to optimize sub-processes.
Increased customer satisfaction: Traceability enables reliable information to be provided on delivery dates and product quality - without the need for time-consuming research.
![[Translate to English:] Icon Losgröße 1](/fileadmin/AutoID_RFID/rfid-tracking/traceability/icon_lossgroesse_1.png "[Translate to English:] Losgröße 1"){kind=icon}
Efficient production with batch size 1: Traceability solutions enable efficient production of individual orders with increasing product variance and reduced production quantities per batch down to batch size 1.
Traceability in discrete manufacturing
In discrete manufacturing, individual, identifiable products are manufactured, such as cars, machines or electronic devices. In this context, traceability involves tracking each individual component and assembly throughout the entire production process. As a result, traceability is used to automatically store which source components and assemblies have been incorporated into the respective serial number-managed end product.
Traceability requirements in discrete manufacturing
- Individual part tracking: In discrete manufacturing, individual components and assemblies must be tracked, often with unique serial numbers. This means that each part can be identified and tracked individually.
- Assemblies and assembly processes: Tracking sub-assemblies and their assembly is critical. It must be ensured that each assembly has been correctly mounted and that all components have been properly installed. In the event of an error, causes can also be localized quickly.
- Complex bills of materials: The management of bills of materials is necessary because products often consist of many individual parts that may come from different suppliers.
Use case: Traceability in bumper production
A leading automotive supplier has used GRAIDWARE and RFID technology to digitalize the entire production and logistics chain for its bumpers - from injection moulding to assembly. The result: maximum transparency, optimized processes and reduced error rates.
As early as the first production step, each bumper is given an individual RFID tag with which it remains uniquely identifiable throughout the entire process.
- Article is linked to process data directly at the machine
- Documentation of tool, worker and system used
Benefit: Sources of error can be traced back exactly to the production cell - the basis for well-founded root cause analyses.
Each component remains clearly identifiable even during the painting process - for maximum traceability in the event of quality issues.
- Automatic assignment of color batches to each component
- RFID-based detection of the position on the painting rack
- Traceability of potential process deviations
Benefit: Sources of error can be narrowed down specifically to the paint batch and rack location.
At the inspection stations, RFID enables contactless identification of components - quickly, reliably and without damage.
- Display of product-specific information and test instructions on the GRAIDWARE terminal
- Digital recording of fault zones and features
- OK/NOK bookings with feedback to the ERP system
- Data acquisition for subsequent error statistics (e.g. Pareto analyses)
Benefit: Efficient testing processes and precise error documentation for quality assurance.
After painting, several RFID readers monitor the storage of the bumpers in defined containers and storage locations.
- Checking the correct container allocation
- Automatic recording of the warehouse position
- Seamless inventory recording in the system
Benefit: Full inventory security - no manual tracking necessary.
In the final step, each component is assigned to a specific customer order - including tracking of the assembly parameters.
- Linking articles and orders via RFID
- Automatic recording of the assembly materials used
- Documentation of worker, workstation and time
- Traceability of all assembled batches on the end product
Benefit: Complaint errors can be assigned exactly - complaint management becomes measurably faster and more precise.
FAQ: The most frequently asked questions about traceability
Traceability is important to ensure the quality and safety of products, comply with legal regulations, carry out recalls efficiently and increase transparency in the supply chain.
Key benefits include improved quality assurance, greater supply chain efficiency, improved customer confidence, improved recall capabilities and compliance with regulatory requirements.
Implementation involves several steps: first, a needs analysis is carried out to define which objects should be traceable - such as load carriers or individual containers. In this step, the necessary processes are also determined in order to ensure seamless documentation. The next step is to select the appropriate technology that offers the greatest benefits for the specific application. Questions regarding integration into existing systems must also be clarified in advance. Finally, employees should be trained and the system should be continuously monitored and improved.
The duration can vary greatly depending on the complexity of the processes, the size of the company and the technologies selected. As a rule, it can take anywhere from a few months to a year.
We will be happy to present solutions for your industry and your processes. Talk to the specialists for SMEs.
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