Efficient window manufacturing with RFID technology from GERA-IDENT

Digital order tracking and process optimisation in industrial practice

A leading manufacturer of windows and doors has comprehensively digitised and automated its manufacturing processes with the help of RFID technology. The aim was to enable seamless traceability of components, reduce sources of error and optimise the control of production processes – even with a high degree of variant diversity and complex processes.

Initial situation: complexity and media discontinuity

The paper-based production process used until then was prone to errors and offered little transparency regarding the whereabouts of individual parts or assemblies. Delays or misallocations occurred regularly, especially at manual workstations. A new electronic order management system was intended to close this gap – provided that reliable identification of all components could be ensured.

Solution: UHF RFID instead of barcodes

After a comprehensive feasibility analysis, the company – together with GERA-IDENT – decided to use UHF RFID technology. The decisive factors were contactless readability without visual contact and the possibility of inconspicuous attachment to painted wooden components. UHF RFID also allows bulk recording and longer ranges – ideal for an industrial environment.

Integration into production

At every stage of the manufacturing process – from the milling machine to painting and quality control to final assembly – fixed or mobile RFID readers capture the data from the smart labels. A direct connection to the ERP system ensures transparency at all times regarding the location of each component and the customer order to which it is assigned. In addition, the RFID data supports the automated control of robotics, conveyor technology and manual stations.

Technical challenges and solutions

The introduction required tailor-made solutions – particularly with regard to the adhesion of RFID labels to untreated wood, readability in metal-containing environments and the processing of thicker labels by specialised RFID printers. Different types of wood and component sizes were taken into account by making individual adjustments to the reader placement and configuration.

Results

• Complete parts tracking across all production stations

• Fewer errors, faster processes

• Efficient error management through immediate feedback

• Automation and reduction of workload for employees

• Future-proof scalability for growing requirements

Learning points for businesses

• Define goals, but remain flexible

• Plan test phases

• Actively involve employees

• Early coordination with plant manufacturers

• Implement UHF RFID only with experienced partners

Conclusion

The project demonstrates how RFID technology creates real added value in manufacturing – from improved process control to intelligent automation. The solution is scalable, sustainable and transferable to many industrial applications.

👉 Would you like more information or have specific application questions? GERA-IDENT provides support from feasibility analysis to fully integrated solutions.

 #RFID #UHF #SmartLabel #Industry40 #WindowConstruction #WIOT #DigitalProduction #GERAIDENT