Revolutionizing Manufacturing and Supply Chains with RFID Solutions

RFID adoption is accelerating across global supply chains and manufacturing facilities. The warehouse RFID market is expected to grow from USD 8.43 billion in 2024 to USD 23.56 billion by 2034, a compound annual growth rate of 10.8%. This growth reflects how organizations are prioritizing real-time visibility, efficiency, and compliance.

Operationally, RFID can transform accuracy and productivity. Research shows RFID can raise inventory accuracy from around 63% to 95%, while cycle counting can increase from a few hundred items per hour to more than 20,000. Companies also report an 80% improvement in picking and shipping accuracy and up to a 90% reduction in receiving time.

Zebra Technologies is leading this transformation with a complete portfolio of RFID solutions. From rugged handhelds like the MC3400 RFID and TC58, to high-performance fixed readers such as the FX9600 for chokepoint automation, Zebra delivers RFID devices designed for demanding industrial environments. Paired with SMG3’s expertise in designing scalable RFID strategies, these technologies turn RFID from an ambitious idea into a powerful operational tool.

RFID Trends and Industry Growth

RFID adoption is gaining momentum in both manufacturing and transportation and logistics. North America is expected to hold 26.7% of the global warehouse RFID market in 2024, driven by early adoption and a strong focus on supply chain efficiency. In fact, 58% of warehouse leaders plan to deploy RFID technology by 2028.

Zebra RFID solutions are built to meet this demand. Mobile devices like the MC3400 RFID and TC58 provide flexibility for handheld scanning, while the FXR90 Ultra-Rugged Fixed Reader and FX9600 handle continuous, high-volume reads. RFID inlays such as the ZBR2100 and ZBR4100, paired with the ZQ630 Plus Mobile RFID Printer, make tagging assets simple and efficient. Software platforms like Zebra MotionWorks Enterprise and IoT Connector enable large-scale management, analytics, and workflow automation.

RFID Operational Impact

RFID is most effective for tracking pallets, totes, equipment, or high-value assets rather than very small, individual items. For large-scale projects, such as full facility coverage or real-time location systems (RTLS), RFID can deliver enterprise-wide visibility, although these solutions carry higher initial costs. Smaller-scale deployments, such as pallet tracking or tool crib accountability, are highly impactful entry points with faster ROI.

Measured improvements include:

• Inventory accuracy: 63% to 95%
• Cycle counts: 200 items/hour to more than 20,000 items/hour
• Shipping/picking accuracy: 80% improvement
• Receiving time: 90% faster

RFID’s scalability makes it easy and practical to start small, expand to additional workflows, and eventually progress toward full automation.

Use Case 1: RFID Tracking for Inventory-on-the-Move

RFID creates significant efficiencies in supply chain visibility. See this example for transportation and logistics, which utilizes RFID to track pallet movement within trucks across dock doors.

Process:

• Tag pallets with ZBR2100 or ZBR4100 inlays.
• FX9600 fixed readers provide continuous high-volume scanning.

Benefits:

• Reduces manual barcode scanning.
• Improves shipment verification and reduces lost loads.
• Provides real-time visibility into on-site and in-transit inventory.

Use Case 2: Managing Valuables with an RFID-enabled Workflow

RFID offers an innovative solution for controlling high-value tools and equipment. Discover this innovative solution for a manufacturing operation, which optimizes resource management with an RFID-equipped supply cage and streamlined workflow.  

Process:

• Employees are required to use RFID-enabled badges for access to the supply cage.
• Each tool is tagged with a passive  ZBR4100 RFID tag.
• FX9600 fixed readers at cage entry record check-in and check-out events.
• Optional BLE tags and beacons enhance location tracking within the facility.

Benefits:

• Reduces tool loss and time wasted searching for equipment.
• Improves accountability by identifying the last known user.
• Creates an auditable record of usage and return compliance.

What’s Your RFID Use Case?

RFID is no longer experimental; it’s a proven tool driving real results across manufacturing, warehousing, and the supply chain. But successful implementation isn’t just about choosing the right tags or readers. It starts with making sure your infrastructure, workflows, and data systems are RFID-ready.

That’s where SMG3 comes in.

We help businesses assess their current environment to determine the best path to RFID adoption. From identifying the right use cases to ensuring your wireless network and mobile environment are ready to support the technology, we create a tailored roadmap that aligns with your operational goals.

Whether you aim to improve inventory accuracy, meet compliance requirements, or gain greater supply chain visibility, Zebra RFID solutions, strategically deployed by SMG3, can deliver a measurable ROI.

Not sure if you’re ready?
Schedule an RFID Readiness Assessment with SMG3 and uncover what’s needed to build a solid foundation for scalable, long-term RFID success.