RFID Inventory Tracking and Cycle Counting with Autonomous Mobile Robots

By 2022 the RFID market is expected to be worth $22 billion according to a recent Research and Markets report. This global value and the impressive 13.2 percent CAGR for the industry is a result of the thousands of companies that have already discovered the value RFID can bring to their business, and thousands more that are expected to discover this value in the coming years.

RFID Inventory Tracking with Autonomous Mobile Robots (AMRs) is the Future

Even for those companies that have fully embraced RFID, the infrastructure investment required to cover large warehouses with fixed readers is cost-prohibitive. Instead, employees are often tasked with walking the floor with a hand scanner once a week, or less, to complete a cycle count. Using AMRs fitted with RFID scanners, cycle counting and even a full inventory audit can be completed in minutes, multiple times a day, without the need for human intervention.


Automated cycle counting with TagSurveyor reduces inventory loss by collecting, locating, and tracking RFID tags on products and bins within warehouses and factories.

Let’s take a real-world example of an automotive manufacturer and its reusable containers. Prior to adding RFID tags to their containers and installing RFID readers at their dock doors, they might have been losing 15-20 percent of their total container stock annually. Replacement and expedited delivery of new containers could easily add up to millions of dollars in cost every quarter. By adding the insights that RFID inventory cycle counting and monitoring provides, not only are they losing far fewer containers, but they can track stock levels and prevent the fees associated with rush delivery of new containers.

Of course these insights only go as far as the dock doors. They know that a container should be in the building, but where is it? An intelligent and sensor packed AMR RFID solution can tell you where each of your assets is physically located within your facility in near-real time. Instead of spending the time and manpower to laboriously hunt down an item in a 300K square foot facility, you can use an RFID AMR to provide regular updated maps of your entire inventory. Cycle counting, which was once relegated to a once a week or even once a month, now becomes daily and automatic.

So how exactly do RFID equipped AMRs collect this data? Like all AMRs, an AMR with an integrated RFID reader does not require any modification to your working environment. AMRs can safely and precisely navigate through your facility with sensors like a wide-angle laser scanner and 3D sensor.

By moving a reader by your stock in a steady and consistent speed, not only do you dramatically increase the chance of a getting a good read from a tag — regardless of its orientation — but you can triangulate the location of a tag. Because the AMR always knows where it is in your facility and uses multiple antennas to collect data, you receive high-confidence location data in a short period of time.

Finally, AMRs can complete an inventory once a day, multiple times a day, or even collect data continuously. Long battery life means that AMRs can work with or around your shift schedule and, depending on the size of your facility, one or a small number of AMRs can provide 24/7 coverage.

Insights from RFID AMRs Lead to Increased Asset Use and Material Handling Optimization

Real-time insight into where your assets are is great, but it can also help you to better use those assets and even make better production decisions based on that data. Let’s say you need to know whether to do another run of a particular high-value part. What is your current stock level? Where is that stock? If you were to do another run, would you have enough of the correct container to hold those parts?

If your RFID solution includes an AMR, then you’ve already got the answers at your fingertips. Even just knowing where your containers are could improve efficient use of those containers by reducing additional container purchases —  especially when specialty part racks cost $3,000 apiece. 

If your RFID solution includes an AMR, then you’ve already got the answers at your fingertips. Even just knowing where your containers are could improve efficient use of those containers by reducing additional container purchases —  especially when specialty part racks cost $3,000 apiece. 

When you can see assets moving through a facility over the course of a day, inefficiencies become clear. Are container spares being moved to one side of a facility only to trucked back later in the day? Is valuable high-velocity space being taken up with slow moving inventory? A birds-eye view into the real-location of your assets and their movement is the best way to answer these questions and more.

Cycle Counting and In-Warehouse Inventory Audits

Some have touted drones as the future of RFID scanning in storage yards and other outdoor locations and this very well may be true. They are not appropriate, however, for indoor warehouse settings. Few drones can fly for much more than 20 minutes at a time and they still require a trained human pilot. To get safe, all-day work life without adding headcount, AMRs are the way to go. Reliable, and far less likely to fall out of the sky, AMRs are the perfect in-warehouse piece to a complete RFID asset tracking solution.


RFID AMRs serve as dedicated automated data collection solutions and can also complement existing RFID inventory tracking strategies. LEARN MORE: http://bit.ly/2RQwZWP.

Another advanced piece of an RFID solution is retrofitting forklifts with RFID readers. This can help with accuracy of slotting, pallet picking, and cross-docking operations. Unfortunately these readers are not intended to provide the kind of total warehouse coverage that a high accuracy cycle count demands.

A dedicated AMR on the other hand, reliably and repeatedly travels to all the locations in your warehouse that you want scanned. No pros and cons discussion here. In one pass, an RFID AMR can read RFID tags on both pallets at ground level and items on shelves dozens of feet above the ground.

By adding an RFID AMR to your total RFID solution you’ll be able to fulfill the promise of total asset visibility and tracking without adding people or modifying your infrastructure.

If you would like to learn more about how Fetch Robotics’ material handling and automated data collection solutions can improve throughput, efficiency, and productivity in your facility, please see the links below. If you would like to discuss your immediate needs now with one of our solutions experts, you can schedule a free consultation here.


Learn More About How Fetch Robotics’ Solutions Improve Throughput, Efficiency & Productivity, While Working Alongside People:

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