Management:
Corporate
Strategy for Dramatic Productivity:
Shortening Inspection Time by 90%
by
Professor Emeritus Akira Ishikawa
Former
Dean, GSIPEB
Senior
Research Fellow, ICC Institute,
Doctoral
Program Chair
Definition
of Radio Frequency Identification (RFID)
In
this section, I will discuss the technology of Radio Frequency Identification (RFID),
which is a way to identify objects using electromagnetic waves. In most cases,
it refers to technologies that can acquire/transmit information obtained from
tags containing ID information, via short-distance communications using
electromagnetic fields or radio waves.
Specifically,
a winning combination is to have Radio Frequency (RF) and Integrated Circuit
(IC) tags converge with the wireless technology of readers that can read its
data. However, since such tags can be attached to various objects and even onto
human beings, they can be useful in monitoring and verifying positions and
shifts in positions, and therefore reducing inspection times.
Speedy
and accurate distribution support
An
example is the distribution reforms through the application of a monitoring and
tracking system for pharmaceutical products via the use of RFIDs by Eisai
Distribution Co., Ltd. (Atsughi-shi, Kanagawa, President Jiro Kimura) and
Sato Holding Corporation (Meguro-ku,
A
feature of the system include a one-way use in the original packing (which is
easy to install) of psychotropic drugs, which require strict control. It is
also designed for shared use among several companies; in this case, factories,
distribution centers, and agencies.
Zero
Error
As
part of a “product substitution experiment” (which was carried out without informing
company workers), surprise inspections, which involved gauging the accuracy of
human inspections were carried out for a period of two months. The results
registered a 4% error rate. In contrast, when RFIDs were used, the results
showed a completely error-free, 100% accuracy rate.
In
terms of efficiency and time saved, the IC tags succeeded in producing a super
effect/productivity surge, as indicated in Fig. 5.1, which shows a comparison
of inspection times. What had taken 20 to 30 minutes for visual inspection
(with the aid of a delivery confirmation checklist) was reduced to only 2 to 3
minutes when IC tags were used to carry out the inspections.
Fig.
5.1 A comparison of Inspection-time (x
axis — Number of packages; y axis — Inspection times). Source: Japan
Automatic Identification System Association, “Findings of Trends in the
Automatic Identification Apparatus Market — Although down by 9% in 2007, a
slight increase is forecast for 2009”, “JAISA Bulletin,” 2009 Summer Edition,
Vol. 11/No. 2, 2009.
But
there was more to the super effect. It raised the sense of security, making it
less stressful for addressees and delivery workers. The reduction of stress for
patients, their families, and for people working in medical institutions,
particularly licensed nurses, is also priceless.
According
to the 2008 report compiled by the non-profit organization, Japan Council for
Quality Health Care (Chiyoda-ku, Tokyo, Chief Director, Tetsuo Ihara), there
were 1,440 medical accidents reported and a total of 220,000 medical incidents
reported as well. While medical incidents do not amount to medical accidents,
it is still extremely desirable to see the number of such incidents decrease
even if it is just by a little.
All
the more, when an error occurs, time is also lost to remedy the error, so this
is also a factor that cannot be ignored.
The
Pros and Cons of Two Methods
When
classifying RFID tags by power source, we can classify them into the passive or
active type. The former does not have a battery inside and operates by adjusting
electromagnetic waves emitted from reader-writers, so they are cheap and do not
require much maintenance. But their drawback lies in their short communication
range, extending only several meters.
The
latter, on the other hand, operates by drawing power from the battery in it, so
its communication range extends much further — no doubt a super effect.
However, its drawback is that it is limited by its battery life, thus requires
maintenance. Furthermore, it is relatively expensive.
When
examining the RFID tag by frequency band, another super effect becomes evident
here as well. In the case of the long wave frequency band (below 135 KHz), the
maximum possible communication range extends to 0.3 m. Although a relatively
long antenna is required, it is resilient to the impact of water and dust.
In
contrast, in the case of the microwave frequency band (2.45 GHz), the
transmission method changes from the electromagnetic induction method to the
Hertzian ray method and the communication range extends to 2 m, a one-digit
difference.
Although
a short-length antenna suffices, this has the drawback of being vulnerable to
the impact of water and dust.
Since
the RFID tag’s performance markedly varies by the power source it uses and by
its frequency band, it becomes necessary to make use of it in a way that
leverages its characteristic properties. However, compared to the conventional
bar code, the RFID is clearly the winner in many ways; in terms of recordable
data capacity, which is larger by two digits, amounting to several kilobytes;
in terms of its maximum communication range, which is comparably larger
(single-digit meters vs. dozens of centimeters); in terms of its ability to
make simultaneous readings of multiple sources; and in terms of its
penetrability (identifying individual units behind obstacles such as
cardboards).
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