Security & Logistics System using RFID
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
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.
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
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.
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.
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.
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
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.
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