Introduction
How the Ceramics Industry achieved 99%+ accuracy and optimized mould maintenance with RFID
Emilceramica, part of the prestigious Marazzi Group, has implemented a cutting-edge system based on RFID technology and InfinityID’s software for the management and traceability of industrial moulds.
The project transformed manual, suboptimal processes into an automated digital workflow, ensuring effective predictive maintenance and a drastic reduction in machine downtime. By integrating IoT hardware with a dedicated software platform, the company gained total visibility into the lifecycle of these critical, high-value production components.
Elimination of Machine Downtime
Warehouse Optimization
Operational Cost Reduction
Seamless Integration
The Client: Emilceramica and the excellence of "Made in Italy" Ceramics
Founded in 1961 in Fiorano Modenese, Emilceramica is a historic benchmark for excellence within Italy’s renowned ceramic district. Specialising in the production of ceramic floor and wall tiles, the company has established a powerful international presence, now distributing its solutions in over 70 countries.
To uphold its high quality standards, Emilceramica chose to adopt RFID technology to digitise the lifecycle of its moulds. This initiative simultaneously targets industrial inefficiencies by transforming maintenance from a reactive approach to a predictive one.
This strategic shift has enabled the company to slash operational costs and eliminate unplanned machine downtime.
The challenges in industrial mould management
Before InfinityID’s intervention, mould management presented several critical issues that directly impacted profitability and production flow.
Key operational challenges
- High maintenance costs: mould maintenance expenses amounted to approximately €20,000 per year, highlighting the need for precise traceability to optimize these outlays.
- Inaccurate monitoring: tile production was not accurately tracked, making it difficult to predict actual mould wear and tear.
- Suboptimal maintenance: interventions were performed without a reliable data foundation, leading to production waste (scrap) and unplanned downtime.
- High search times: significant difficulties arose when locating specific moulds within complex warehouses and extensive production areas.
The RFID Solution: Traceability and smart maintenance
The implemented solution integrates high-durability RFID tags, fixed readers on the presses, and handheld mobile devices for end-to-end management.
Key operational challenges
- Tag RFID: applied to every mould and press, these are designed to withstand the intense thermal and mechanical stresses typical of the ceramic environment.
- Press readers and antennas: configured to automatically detect the mounted mould and monitor its activity in real-time, providing up-to-date data on the number of strokes or production cycles.
- Android handhelds with item locator: portable devices that enable the location of a specific mould from up to 4 metres away, simplifying search operations and inventory management.
- InfinityID’s software: the platform that centralises data, linking the mould’s master data (Digital Twin) to its unique RFID tag identifier.
These integrated elements enable Emilceramica to optimise automatic monitoring and maintenance cycles, leading to tangible cost savings and immediate time efficiency.
Key system features
The adopted solution offers advanced functionalities that radically transform the operational management of moulds:
- Accurate stroke counting: precise monitoring of the number of cycles or strokes performed by each mould while on the press.
- Predictive maintenance: automation of control systems to schedule routine maintenance at the exact moment required, allowing for optimal planning based on actual wear and tear.
- Asset retrieval (item finder): a feature that guides the operator directly to the desired mould, drastically reducing search times within the facility.
- “Press view” data analysis: a dedicated dashboard that displays all tags read by a specific press over the last 24 hours. Data can be exported to Excel or CSV for in-depth performance analysis.
Measurable results: ROI and operational benefits
The integration of RFID technology and InfinityID’s software has transformed internal logistics for the Marazzi Group.
KPIs e success metrics
- Traceability and data accuracy (+99%): achieving an optimal match between physical assets in the plant and the digital records in the system, effectively eliminating manual errors
- Warehouse management cost reduction (-30%): streamlining loading, unloading, and inventory counting processes, resulting in a direct reduction of logistics expenditure.
- Reduced maintenance costs: transitioning from high historical spending to predictive maintenance ensures interventions occur only when necessary, significantly extending the lifespan of the moulds.
- Return on investment (ROI): high operational efficiency and generated savings allow for a rapid payback period, effectively doubling the value of the initial investment.
Strategic benefits
- Elimination of Machine Downtime: thanks to maintenance scheduled using real-time data, unplanned breakdowns and production stops have been almost entirely eliminated.
- Warehouse Optimization: real-time inventory tracking and a significant reduction in waste caused by lost assets or excessive mould wear and tear.
- Operational Cost Reduction: streamlined logistics and a marked decrease in manual processing times.
- Seamless Integration: the system was successfully integrated with the existing corporate ERP (such as SAP or Microsoft Dynamics) without any disruption to ongoing productivity.
