| Summary: RFID turns WIP tracking from something people do manually into something that happens automatically as production moves forward. Fixed readers at key points, handheld devices for flexibility, and tags that carry production data beyond just identification numbers; together, these give manufacturers a continuous, accurate picture of where everything is and what stage it is at. The TDM example shows what that looks like in practice: faster workflows, less downtime, real-time reporting, and integration with broader enterprise systems. |
RFID for WIP Tracking Provides Visibility and Value
Being able to track and have complete visibility into your work in process (WIP) and all the parts moving through your supply chain is obviously valuable.
It’s even better when you can do it automatically and in real time.
Thankfully, there’s a proven and cost-effective way to achieve this with radio frequency identification (RFID).
Understanding RFID & Its Advantages
RFID relies on printed tags to identify and track assets as they move through your supply chain or processes.
Each tag contains a radio transmitter that operates like Wi-Fi, transmitting data wirelessly to a scanner, which reads the tag remotely.
Unlike barcode scanning, which requires line-of-sight access to the barcode and manual scanning, RFID automates data capture and tracking.
As a part or finished good moves through your processes and workstations, fixed RFID readers automatically detect and identify it.
These devices, such as Zebra’s FX9600 fixed RFID reader, are typically placed in strategic locations such as doorways and workstations. They read RFID tags automatically without requiring human labor.
As an alternative, operators and workers can use handheld RFID readers, such as Zebra’s MC9190-Z model. Handheld RFID readers read tags remotely, at long ranges, while also serving as mobile computers to run your business-critical software applications.
Importantly, RFID tags can also contain complex work instructions, bills of material, and tracking numbers. These allow operators to track and direct parts through your processes automatically, with easy access to all the part-specific information and instructions they need.
They can access it all on mobile computers, using a user-friendly app that also allows operators and managers to access real-time WIP tracking and reports.
A Real-World RFID for WIP Case Study
A perfect example of RFID’s value is its use by Troy Design & Manufacturing (TDM), a Ford Motor Company subsidiary. TDM now uses RFID to track, monitor and guide more than 150 daily vehicle conversions at its Chicago Modification Center (CMC).
TDM primarily specializes in prototype and short-run metal stamping, but also handles vehicle conversions. Ford manufactures police interceptors at a nearby plant. The interceptors are then sent to TDM for customization to meet the requirements of local law enforcement units including colors, lights, and other unique features. To further streamline these operations, TDM also leverages advanced technologies such as mobile device management solutions to enhance efficiency, ensure secure communication, and support real-time updates throughout the conversion process.
In launching this new endeavor, the company realized a manual, paper-based tracking system wouldn’t be efficient enough to handle operations for 150 vehicles per day. Barcoding and fixed terminal entry simply wouldn’t provide the required level of automation.
To find a better alternative, TDM turned to the team at Lowry Solutions and worked together to develop an ideal solution.
A major component of the TDM plan was using Zebra RFID infrastructure technologies, including an RFID scanner, to achieve true, automated WIP tracking with real-time visibility into its entire vehicle conversion processes from receipt to completion.
The system has delivered an array of benefits, including streamlining workflows, preventing downtime, and helping TDM’s operators stay more focused on their tasks with less need to worry about paper-based documentation or tracking duties.
VIN numbers, tracking numbers, work instructions, BOMs, and even time and date stamps are all captured and communicated automatically.
Since the Lowry WIP software interfaces with Ford’s corporate database, TDM also uses RFID to send Ford real-time reports of vehicle receipt, production progress and shipping updates.
Using RFID for Work in Process (WIP) Tracking
Walk through most manufacturing facilities, and you will find the same problem somewhere on the floor. A batch of components that nobody can locate. A production stage is sitting idle because the parts for the next step have not shown up yet. Someone walking around with a clipboard, trying to figure out where a job is in the process.
These are not rare situations. They are what happens when tracking relies on people manually scanning, recording, or updating status at every step. It works until the volume gets high enough, or the operation complex enough, that human tracking simply cannot keep pace.
RFID solves this by removing manual scanning from the equation almost entirely. Tags communicate with readers automatically as items move through the facility. No one has to stop and scan anything. The system knows where everything is because it tracked every movement as it happened.
What RFID Actually Does
Each RFID tag contains a small microchip and antenna. As tagged items pass within range of a reader, the reader picks up the signal and logs the data, item identity, location, timestamp, whatever the system is configured to capture.
The key difference from barcodes is that RFID does not require line of sight. A barcode has to be physically presented to a scanner, one at a time, by a person. RFID readers pick up every tag in range automatically, often reading dozens of items simultaneously, without anyone doing anything.
In a high-volume production environment, that difference is enormous.
What makes RFID particularly useful for WIP:
- Items are tracked continuously without production stopping for manual scans
- Multiple components are read at once rather than one at a time
- Human error has been removed from the data capture process
- Real-time location and status are available across the whole facility
- Reporting happens automatically as production moves forward
How It Works on the Floor
A typical RFID setup for WIP tracking uses two types of readers working together.
Fixed readers — devices like the Zebra FX9600 — get installed at the points that matter most:
- Entry and exit points between production stages
- Workstation positions
- Warehouse doors and loading areas
- Transitions between assembly, testing, and packaging
As items pass through these points, the fixed readers log the movement automatically. Managers can see exactly where every component is in the process without anyone having to report it manually.
Handheld readers — like the Zebra MC9190-Z — give operators flexibility for situations where fixed infrastructure is not practical:
- Scanning multiple items at once across a storage area
- Conducting spot checks on inventory
- Managing exceptions or investigating discrepancies
- Running business applications directly on the device
Together, fixed and handheld readers cover the facility completely. Nothing moves through production without being recorded.
More Than Just Location Data
Location tracking is the most obvious use of RFID, but the tags themselves can carry significantly more information than just an identifier.
A single RFID tag attached to a component or assembly can hold:
- Work instructions so operators know what needs to happen at each stage
- Bills of materials listing what components are required
- Serial and batch numbers for traceability
- Routing information showing the correct path through production
- Quality control checkpoints that need to be completed and verified
- Time and date stamps build a complete production history
In modern setups, this data connects directly to mobile applications and enterprise systems. An operator picks up a tagged item, relevant instructions and status information appear on their device, and when the work is done, the system updates automatically.
What This Looks Like in Practice — TDM and Ford
Troy Design and Manufacturing, a Ford subsidiary, runs a vehicle modification center in Chicago, processing more than 150 conversions per day. These are not simple jobs — police interceptors getting custom lighting, interior modifications, and specialized equipment installed across a highly complex workflow.
Before RFID, managing that volume with paper records and barcode scanning was genuinely difficult. Manual scanning at every step created delays. Information got missed. Tracking the status of 150 vehicles simultaneously through a multi-stage customization process was more than the old system could handle cleanly.
TDM partnered with Lowry Solutions to deploy a full RFID-based WIP tracking system using Zebra infrastructure — fixed readers positioned throughout the facility, handheld devices for operational flexibility, and RFID tags on every vehicle and component.
What changed after implementation:
- Workflows became smoother as automatic tracking replaced manual scanning at each stage.
- Downtime dropped because operators were not stopping to scan items by hand.
- Managers had real-time visibility into where every vehicle was in production at any moment.
- VINs, timestamps, work instructions, and status updates are all recorded automatically without manual input.
- Direct integration with Ford’s corporate databases gave planning teams live data on vehicle receipt, production progress, and shipping status.
That last point matters beyond just the facility itself. When the tracking system feeds real data into corporate planning systems in real time, the coordination between production and the broader supply chain improves significantly.
Why Manual Tracking Breaks Down at Scale
The case for RFID in WIP comes down to three specific things that manual and barcode-based systems struggle with as volume increases:
Speed — RFID captures data instantly as items move through the facility. There is no pause, no scan, no human step in between. At high volume, that continuous capture makes a measurable difference in throughput.
Accuracy — Manual data entry introduces errors. Barcodes get missed or misread. RFID reads are automatic and consistent. The data in the system reflects what is actually happening on the floor rather than what someone remembered to record.
Visibility — When tracking is manual, visibility is always slightly behind reality. Someone updates a status after the fact, or forgets to, or records it in the wrong place. RFID visibility is current because the system updates the moment something moves.
Contact Lowry or call us at 1-888-881-2477 to learn more about RFID and how it can help your business.
Frequently Asked Questions
It is a system that automatically tracks parts and assemblies as they move through production using wireless tags and readers — no manual scanning required. It matters because visibility into WIP directly affects how efficiently a facility runs. When you know where everything is in real time, delays get caught earlier, and workflows stay on track.
Barcodes require someone to physically present each item to a scanner, one at a time. RFID readers pick up every tag within range automatically and simultaneously — without anyone doing anything. In a busy production environment, that difference translates directly into speed and accuracy.
Manufacturing, automotive, aerospace, logistics, and healthcare see the biggest gains — anywhere with high volumes of components moving through complex multi-stage processes where manual tracking simply cannot keep up.
Yes — and this is one of the more underappreciated aspects of the technology. Tags can carry work instructions, bills of materials, routing steps, serial numbers, quality checkpoints, and timestamps. Operators get what they need without hunting through separate documentation.
It removes the dependency on people to capture data at each step. Manual processes and barcode systems both require human intervention at every scan point. RFID records movement automatically, which means the data is always current, errors from manual entry disappear, and production does not have to slow down to be tracked.
A Horizons Talent Alumnus and Microsoft Certified Systems Engineer (MCSE), the author brings a proven track record of success in senior shared-services leadership roles within large, complex multinational organizations, particularly in the manufacturing sector.
With deep experience at Senior Manager level, they have led strategic customer relationships by understanding core business imperatives, shaping service and solution propositions, and delivering measurable business outcomes.
