Belgian work boot manufacturer Bekina Boots tracks bootmaking process with RFID technology

Manufacturer Bekina Boots uses RFID technology to provide work-in-process (WIP) inventory data for each boot it manufactures, while tracking the automatic identification information its customers will eventually use when wearing the boots in an industrial setting. The system provides unique identification and traceability of polyurethane safety shoes from production to shipment.

Bekina Boots products are manufactured in Belgium and exported to more than 50 countries around the world. The Wellington-style work boots are made from Neotane, a polyurethane developed in the company's lab. Workers in the agricultural market as well as in the fishing, construction and food industries use the work boots, which the company says are designed to be more durable than rubber or PVC boots.

In the long run, customers using this boot will be able to collect RFID electronic tag information for Access Control and security applications in workplaces where RFID Readers are installed. A few years ago, Bekina Boots sought a tracking solution to fine-tune its logistics processes both internally and in its supply chain. Ensure the efficiency of its work in process and logistics by uniquely identifying each product as it is manufactured and shipped to customers. Bekina Boots has traditionally identified each pair of safety boots by their unique SKU through a barcode on the packaging. However, the company wants to automatically recognize and link that identification to each individual boot, not just in the field, but in the supply chain and throughout the lifecycle of the footwear.

In use, Bekina Boots' boot manufacturing process presented unique challenges to RFID technology. Since the polyurethane is injected at 130 degrees Celsius (266 degrees Fahrenheit), the tags need to be resistant not only to heat but also to impacts, and they have to be flexible enough to bend over the life of the boot. During the proof-of-concept, they opted to integrate RFID tags into boots and then separately tested the tags for reading (at the beginning of the manufacturing process) and batching (during internal and external processing).

At the start of production, an RFID tag is programmed and printed on each boot. The tag is then fully integrated into the material of the boot, in a position where radio waves are not interfered by the metal anti-perforation sole. Tag information is then captured through RFID middleware and linked to Bekina Boots' database. In order to continue to identify each tagged boot throughout the production process, fixed RFID readers must be installed at key logistics points. In the packing area, for example, RFID access doors record the exact location of the boots on the shopping cart, enabling packing managers to correctly fill customer orders. Also, other doors in the warehouse are used to link RFID tags to the correct production order.

In the future, UHF RFID access doors will provide additional control for delivery orders and can be used in distribution centers. The solution will improve customer service by ensuring the correct product is shipped in a timely manner, and customers using the boots while wearing them will be part of the future implementation. RFID-tagged safety boots can be used for automatic access control to areas accessible only to certain individuals. This requires workers to be properly registered every time they stop in a secure area, and creating a hands-free scanning process can provide a more automated and hygienic solution than badge scanning.

It is worth mentioning that on the construction site, managers can monitor whether each worker is wearing the necessary personal protective equipment through RFID electronic tags and RFID access doors. Every time a worker enters a job site, just attach an RFID tag to each piece of safety clothing, from helmet to boot, for screening.