Connecting the Factory Floor to ERP: RFID-Enabled Traceability with TrakSYS

In this full-length webinar, Corey Vodvarka, Manufacturing Expert and Lean Six Sigma Black Belt at Parsec, moderates a discussion on effective inventory management and traceability using TrakSYS and RFID. He’s joined by Tim Smith, Senior Industrial Engineer at Hydranautics (a Nitto Group Company), and Jim Flagg, Smart Manufacturing System Architect at Polytron. Together, they explore how RFID technology and the TrakSYS MOM platform were used to improve visibility, streamline inventory processes, and enhance operational efficiency at Hydranautics.

Hydranautics, a global leader in integrated membrane solutions for water filtration, needed a more efficient way to track thousands of products moving through production and distribution. Their existing barcode system limited visibility, required manual effort, and slowed down production. By adopting RFID technology integrated with TrakSYS, Hydranautics was able to automate data collection, reduce human error, and connect the shop floor with ERP systems for real-time insights.

Key topics covered:

• Transitioning from barcode tracking to RFID-based data collection
• Establishing end-to-end product traceability across manufacturing and warehouse operations
• Integrating RFID with TrakSYS and ERP systems (JD Edwards) for seamless data flow
• Using TrakSYS dashboards for real-time production and inventory visibility
• Reducing labor costs and improving efficiency during semiannual inventory counts
• Implementing passive RFID tags for durable, multi-read functionality
• Enabling live dashboards and reports for WIP tracking and warehouse management
• Leveraging RFID and TrakSYS for IoT compatibility and future scalability

Project outcomes:

• 50% reduction in inventory reconciliation time
• Significant labor savings by automating previously manual barcode scanning processes
• Real-time traceability of individual elements and pallets throughout production
• Faster product handling with no line-of-sight required for scanning
• Future-ready infrastructure for expanding RFID use in other areas of the business

Q&A highlights:

• Differences between passive and active RFID tags and why passive was chosen
• Overcoming challenges with tag placement, signal orientation, and antenna configuration
• Integration of TrakSYS with CMMS and data historians
• How RFID supports predictive maintenance and energy efficiency initiatives

Quote from Tim Smith:

“Our first RFID inventory count required only two people to scan the entire factory, and it took about three hours to complete the process—a dramatic improvement from the days it used to take with barcode scanning.”

This case study demonstrates how TrakSYS enables manufacturers to connect systems, people, and processes for a more efficient, accurate, and intelligent approach to inventory management.