Security & Logistics System using RFID
 
  Introduction
 
    Sterlite Industries (India) Ltd (SIIL) is a leading producer of copper in India. SIIL pioneered the
    manufacturing of Continuous Cast Copper Rods in India, and established India’s largest Copper Smelting
    and Refining Plant for production of world class refined copper. Sterlite, a part of Vedanta Resources,
    a London listed metals and mining major with Aluminum, Copper and Zinc operations in UK, India and
    Australia.

    Sterlite —  Tuticorin has a major task in handling logistics for inbound and outbound material
    transportation. On an average in a day there  are approximately 800 to 1000 trucks, tankers entering and
    exiting the gates of Sterlite which itself estimates the size of fleet that needs to be handled.

    There are 2 departments who are directly responsible for making this happen. The logistics
    department and the Security department. 

    Currently the weighbridge application is in place developed on VB6 and  Oracle but the process at
    logistics and security is done using excel spreadsheets and some process are handled manually.
    Hence the immediate requirement is to automate the logistics the security processes and integrate
    the same with the weighbridge system.
 
  The challenge  
 
     To control entire logistics of vehicles movement within the factory premises. 
     To ensure movement of vehicles as per planned route depending on products to carry.  
     To ensure parking space availability at various point of halt in the workflow. 
     To ensure the right material is loaded on to the right vehicle 
     Transforming the entire logistics process of managing truck movements by rolling out Radio Frequency 
       Identification (RFID) technology using passive solution and proximity readers  
     Delivering RFID transponders compliant with emerging EPCglobal standards to advance and support the
       worldwide standardization of RFID technology

  The Solution:

     All the above challenges were addressed by  simply using an identification mechanism, mapping a single
     vehicle to a product it is supposed to carry and track the same till it moves out of the premises. REID,
     Radio Erequency Identification, creates an automatic way to collect information required about a vehicle,
     product, and the workflow that the vehicle needs to follow in the process of loading without leaving place
     for human error apart from also being financially viable..

  How the solution works:

     An REID system communicates through a reader, which broadcasts a signal through an antenna. When a
     transponder (also called tag) enters the antenna field, it receives the signal from the reader. 
     The transponder is ‘charged’with enough power to send back a unique identification code to the reader.  
 
    Transponders

      The transponders or tags are the backbone of the technology and come in a variety of shapes, sizes and
      read ranges to suit different applications. The REID transponders are more than just an identification
      code. The read/write transponders may be used as a data carrier, with information being written to the
      tag's memory and updated on the fly.

    Readers

     REID Readers range from low  power, short-range microreaders to high-powered fully encased readers
     designed for longer lead ranges and also the hand-held readers. These superior ranges of readers
     provide quality communication with the transponders.

  Proposed Solution:

     In this project 2 major modules were developed:

       Logistics module -  which caters to entire process handled in this department starting from automated
       generation of load to be dispatched for the day on the basis of sales order. All further processes like
       allocating appropriate vehicles to appropriate load on the basis of dispatch location and tonnage,
       generation of load advices, defining specific workflow for each product,  alert system on diversion
       from workflow, etc have been automated.

       Security Module -  an interface for viewing the space occupancy at every point in the workflow has been
       provided on the basis of which the vehicles are allowed entry.  The security guard is just supposed to 
       enter the vehicle number and show the REID card to the reader and handover the card to the cleaner of the
       vehicle. All other information of the load to be carried and the specific workflow path to be followed is
       displayed on the screen.  
       This entry,  exit process has been built for inbound, outbound material and also for contractor material.

       Weigh Bridge Module - the existing third party weighbridge application has been interfaced with our
       application.

       Thus by  installing the right equipments and developing a robust application system to manage the entire
       process all the pain areas described above were addressed.

  Key Technologies

       Extensive review and definition of the transponders and readers to be procured and deployed to achieve
       successful rollout of asset level REID tagging
       Rigorous testing enabling reliable recognition of R