Challenge

Innova DIY Kitchens is a leading UK manufacturer, producing over 2.000 kitchen cabinets each week. With such scale, coordinating the supply of components for each kitchen order became a logistical challenge. Panels, frames and accessories for a single kitchen are produced on different lines, and supplied from different warehouse locations, but had to arrive together at the assembly station. This process, previously managed via multiple Excel spreadsheets, was inefficient, error-prone and lacked real-time visibility.

Before implementing RFID, Innova relied on barcode labels manually scanned with handheld terminals at each production station. However, this process was inconsistent, some cabinets were skipped or removed from the sequence to expedite orders, resulting in incomplete and unreliable data in the ERP system.

To improve efficiency and support future growth, Innova needed a robust, automated tracking solution that could provide end-to-end visibility across the entire production process.

Solution

RFID Direct implemented an end-to-end RFID system to digitize component identification and provide real-time supply chain visibility. At the start of production, each kitchen cabinet receives a UHF RFID label. This smart label includes a barcode, human-readable information and an encoded RFID label, linking the item to a specific customer order in Innova’s ERP system.

Impinj & Caen RFID scanners in combination with Times-7 A8060 & A5020 antennas are positioned at key locations throughout production, at key positions in the production lines itself, at both entry and exit points of the manual assembly stations, at the packaging line and at each dock door. These scan points automatically register the movement of products and ensure full traceability across the production process.

In the manual assembly phase, goods-in and goods-out scans verify that each cabinet enters and exits in sequence. Based on these scans, the ERP system automatically triggers the supply of matching doors, drawers and appliances, ensuring just-in-time availability for final assembly. If components are missing or delayed, the system issues alerts, helping to prevent production bottlenecks.

Once cabinets are packed, the RFID labels remain readable even through cardboard packaging, enabling accurate tracking through to the dispatch area. Each customer order is verified via RFID before it is loaded.

All five dock doors are equipped with Impinj R700 reader systems that scan each item during the loading process. This guarantees that every item for a specific customer order is present before departure.