Passive Radio Frequency Identification Project - … · USMC Blount Island Command Passive RFID...

USMC Blount Island Command Passive RFID Report November, 2009

E-1

Passive Radio Frequency Identification

Project

United States Marine Corps

Blount Island Command

Jacksonville, FL


2

Contents

Executive Summary ...................................................................................................................................... 4

Overview of Blount Island ......................................................................................................................... 4

Passive RFID Vision ................................................................................................................................. 4

Marine Corps RFID Commitment .............................................................................................................. 5

Background ............................................................................................................................................... 5

Alien Technology Collaboration ................................................................................................................ 5

Stakeholders ............................................................................................................................................. 6

Project Selection ....................................................................................................................................... 6

Major Results and Accomplishments ........................................................................................................ 6

1. Systems Integration & Training Facility (SITF) ..................................................................................... 9

1.1. Needs Analysis.............................................................................................................................. 9

1.2. Site Analysis ................................................................................................................................ 10

1.3. Conclusion and findings. ............................................................................................................. 12

2. Ship Backload Operation .................................................................................................................... 16

2.1. Current Business Process ........................................................................................................... 16

2.2. Needs Analysis............................................................................................................................ 17

2.3. Site Analysis ................................................................................................................................ 19

2.4. Proof of Principle Deployment..................................................................................................... 26

2.5. Revised Business Process .......................................................................................................... 27

2.6. Summary and Conclusions. ........................................................................................................ 29

2.7. Anticipated next steps. ................................................................................................................ 31

3. Consolidated Memorandum Report (CMR) Inventory......................................................................... 32

3.1. Current Business Process. .......................................................................................................... 32

3.2. Needs Analysis............................................................................................................................ 33

3.3. Site Analysis ................................................................................................................................ 34

3.4. Proof of Principle Deployment..................................................................................................... 35

3.5. Revised Business Process .......................................................................................................... 37



4. Container Load / Mobile Load (CL/ML) ............................................................................................... 41


3


4.2. Needs Analysis............................................................................................................................ 41

4.3. Site Analysis ................................................................................................................................ 42

4.4. Proof of Principle Demonstration Deployment ............................................................................ 45

4.5. Anticipated Revised Business Process ....................................................................................... 47



5. Deployable Automated Cargo Measurement System (DACMS) ........................................................ 49


5.2. Needs Analysis............................................................................................................................ 50

5.3. Site Analysis ................................................................................................................................ 51

5.4. Anticipated Revised Business Process ....................................................................................... 53



6. Appendices.......................................................................................................................................... 54

Appendix A - Passive RFID Tag Testing ................................................................................................ A1

Appendix B - Acronym Listing ................................................................................................................. B1

Appendix C - Container Load / Mobile Load Representative Item Listing ............................................. C1

Appendix D - Letter of Intent .................................................................................................................. D1

Appendix E - Blount Island Command Passive RFID Charter ................................................................ E1


4

Executive Summary

Overview of Blount Island The concept of a Maritime Prepositioning Force (MPF) was first envisioned during the late 1970‟s. The

initial program established in 1979 was called the Near Term Prepositioning Force (NTPF). NTPF used

existing operational force equipment and supplies to load on available ships belonging to the Military

Sealift Command (MSC). These ships were based in Diego Garcia and initial equipment and ship

maintenance was done in Naha, Okinawa and Subic Bay Naval Base. The Marine Corps immediately

recognized the advantages of prepositioning equipment and seized the opportunity to revolutionize

combat readiness.

In March 1983, the Commandant directed Marine Corps Logistic Base, Albany to acquire the assets for

the MPF program. MSC leased thirteen ships for the MPF program. The ships were formed into three

Maritime Prepositioning Squadrons (MPSRONs). MPSRON 1 and 2 were loaded in Wilmington, North

Carolina and MPSRON 3 was loaded in Panama City, Florida. The ammunition for all three squadrons

was loaded at Military Ocean Terminal, Sunny Point, North Carolina.

In 1986, the Marine Corps established the Biennial Maintenance Command (BMC) at Blount Island,

Jacksonville, Florida. In 1989, Blount Island Command was established as a subordinate command to

Marine Corps Logistics Bases, Albany, Georgia. Today, Blount Island Command (BICmd) is assigned

under Marine Corps Logistics Command, Albany, Georgia and is responsible for the Maritime

Prepositioning Ships (MPS) Maintenance Cycle (MMC) operations and oversight of the Marine Corps

Prepositioning Program – Norway (MCPP-N). The area currently occupied by Blount Island Command

was purchased in August 2004.

The Marine Corps prepositioning programs consist of the Maritime Prepositioning Force (MPF) and the

Marine Corps Prepositioning Programs – Norway (MCPP-N). Each program supports the rapid

deployment and assembly of a Marine Air-Ground Task Force (MAGTF) using strategic airlift and

equipment prepositioned aboard forward-deployed prepositioning ships (MPSs) or at geo-prepositioning

sites. Marine Corps Logistics Command (MCLC), through Blount Island Command (BICmd), has the

direct responsibility to ensure and maintain accurate accountability of all prepositioned assets, and

coordinate efforts of liaison/support personnel.

Blount Island Command is located on the eastern half of Blount Island in Duval County, Florida, on the St.

Johns River approximately 10 miles northeast of the business district of Jacksonville and seven miles

east of the Atlantic Ocean shoreline.

Passive RFID Vision The Marine Air Ground Task Force (MAGTF) Deployment Support System II (MDSS II) is the

Commander‟s unit level deployment database capable of planning and supporting rapid military

deployment anywhere in the world. MDSS II enables BICmd to build and maintain a database that

contains the prepositioned Maritime Prepositioning Equipment / Supplies (MPE/S) data, reflecting how

the MAGTF is configured for deployment. It is vitally important that the data contained in MDSS II is

complete, correct, and timely. The processes to enter the data into MDSS II are manual and subject to

human error.


5

In addition to MDSS II data quality, BICmd has the responsibility of accounting for over 8000 garrison

assets. The processes to track and inventory these assets are currently manual. Subsequently, this

recurring effort is extremely time consuming and prone to human error.

There are inherent risks with leveraging new technology to help improve the efficiency and effectiveness

of the Maritime Prepositioning Equipment / Supplies (MPE/S) maintenance process. The Information

Assurance (IA) certification and accreditation requirement for any new information system restricts its

interface with the Marine Corps Enterprise Network (MCEN). Additionally, there is no indoor facility that

provides the means to conduct evaluations or demonstrations of promising off-the-shelf technology

alternatives.

The Passive RFID Vision is to apply the technology to increase business process efficiency, improve data

quality, and increase asset visibility throughout the Maritime Prepositioning Maintenance Cycle where

proven cost effective.

Marine Corps RFID Commitment A Letter of Intent (LOI) was signed by the Commanding Officer, Blount Island Command and Vice

President of Sales, Alien Technology Corporation on 8 January 2008. The LOI established an agreement

between the two organizations to, “…jointly cooperate and develop mutually beneficial passive UHF RFID

opportunities to enhance the logistical efficiencies of the USMC prepositioning programs.”

Background The Deputy Under Secretary of Defense for Logistics and Materiel Readiness (DUSD (LM&R)) distributed

a 30 July 2004 Policy Memorandum that required each service to develop an Implementation Plan for the

use of Active and Passive RFID technologies in logistics business processes. The Headquarters, United

States Marine Corps Deputy Commandant, Installation and Logistics responded to this policy by

publishing the USMC Radio Frequency Identification (RFID) Implementation Plan. Specifically, the

Marine Corps RFID Implementation Plan provides guidance and procedures for the use of data rich active

RFID technology and electronic product code (EPC) compliant passive RFID technology in Marine Corps

logistics and distribution processes.

Alien Technology Collaboration Blount Island Command, their on-site support contractors (Stanley Associates), and Alien Technology

formed a cohesive team dedicated to the completion of this passive RFID initiative. Each entity provided

expertise in the areas of project management and technical knowledge in carrying out the objectives

contained in the Charter. Specifically, the Passive RFID Charter delineated the responsibilities as

follows:


6

Stakeholders The Stakeholders for this project include the USMC Blount Island Command, Alien Technology, Inc.,

Stanley Associates, Inc. and Honeywell Technology Solutions, Inc..

Project Selection Blount Island Command has identified two supporting passive RFID projects and four primary projects for

this scope of effort.

The supporting projects include:

(1) Systems Integration and Training Facility (SITF)

(2) Passive RFID Tag Performance Testing

The primary projects include:

(1) Ship Backload (BL) Asset Tracking

(2) Consolidated Memorandum Report (CMR) Inventory

(3) Container and Mobile Load (CL/ML) Asset Tracking

(4) Deployable Automated Cargo Measurement System (DACMS) Asset Tracking.

Major Results and Accomplishments The results and accomplishments of this project are as follows:

Systems Integration and Training Facility (SITF). The SITF was established to objectively

evaluate new methods and information technology (IT) products for enhancing Blount Island

Command‟s business processes. It provides a segregated network and computer system

infrastructure from the Marine Corps Enterprise Network (MCEN) to avoid Information Assurance

risks associated with new tools. Once a new method or tool is demonstrated to enhance Blount

Island‟s business processes and provide a reasonable return on investment, the SITF provides

Resources BICmd Alien Technology, Inc.

Funding $600K (Matching Funds) $600K

Project Team

(Full and Part

Time Staff)

BICmd Project Management and

oversight

On-site contractor support

(Stanley, Inc.)

Program Manager, Technical Project

Manager, RFID technical support

services as required

Facilities Systems Integration and Training

Facility

RFID Support Center for the purpose of

conducting technical training

Equipment Non-RFID equipment necessary

for the completion of this Charter

All passive RFID equipment necessary

for the completion of this Charter

Software

Tools

Business process related

software

RFID firmware and middleware (device

management)


7

the resources to fully implement the technology by providing hands-on training to the workforce.

Consequently this resource is especially important to an organization, such as Blount Island

Command who has achieved and strives to maintain its International Standards Organization

(ISO) 9001:2000 Quality Management System.

The SITF supported several critical functions for the passive RFID projects:

The SITF enabled the Deployable Automated Cargo Measurement Systems (DACMS)

integration and setup training to take place on schedule during a torrential rain storm that

lasted two days. Over 10 government civilian and contract personnel had traveled to

Blount Island for this event that would have been either delayed or cancelled.

The SITF provided the infrastructure necessary to methodically test the commercially

available passive RFID tags that vary in design and performance. Over 30 different tags

were tested and tag performance data was captured on over 500 applications to MPF

equipment. It enabled the selection of specific passive RFID tags that met or exceeded

the minimum performance of each project.

The SITF provided the infrastructure to test and identify the optimal tag placement on

each prepositioning principal end item and container. Simultaneously it supported the

evaluation and location of the Item Unique Identification (IUID) label placement on these

items. The culmination of this effort resulted in the publishing of an on-line IUID / Passive

RFID Tag Placement Guide currently being used by the maintenance contractor. The

guide provided detailed photographs and textual instructions of proper IUID & passive tag

placement for each item.

The SITF provided the environment needed to integrate and test the Integrating the

Placement and Registration for Identified Material and Equipment (IPRIME). IPRIME

was critical in supporting Blount Island Command‟s process for the IUID / RFID marking

of principal end items and containers.

The SITF provided the means to provide hands-on training of the Blount Island

Command workforce on the new IUID and passive RFID tagging process and tools.

The SITF will continue to provide the capability to evaluate emerging improvements

made to automated identification technology (AIT) and its applicability to BICmd‟s

business processes. It will provide the means to codify the adopted technology and the

applicable business processes by leveraging the training resources. It will also provide

the means to maintain the IUID / Passive RFID Tag Placement Guide as new

prepositioning equipment is introduced to the MPF community.

Ship Backload (BL) Asset Tracking. The passive RFID infrastructure was established to

enable the tracking of assets being loaded to a Maritime Prepositioning Ship (MPS). Six Mobile

Outdoor Portals and one fixed reader assembly was assembled and delivered to Blount Island

Command for this purpose. The USNS Pless Backload served as the means to gather and

evaluate the passive RFID performance data. The passive RFID system had a 94% success rate

at correctly and completely identifying the tagged items being loaded to the USNS Pless. Of the

33 missed tag reads from PEIs, 26 of them can be corrected either by training or proper tag

placement on the PEI. If these were corrected, the estimated performance would be 98%.

The performance of the passive RFID was compared to that of the active RFID during a

backload. The best active RFID performance in tracking assets being backloaded was 88%.

However the average active RFID performance over the past 6 ship‟s backload was 81%. Many


8

of the active RFID failures are associated with the use of batteries. This failure cause is

completely removed with the use of passive RFID technology.

The passive RFID avoids this failure cause and associated recurring costs all together. Moreover

the cost of the passive tags used for PEIs and containers in this project is estimated at $4 each.

Generally, the passive tag suppliers use a pricing schedule that decreases unit cost with volume

orders. The common active tag, Savi ST-654, can cost up to 20 times that of the passive tag.

The batteries for the active tags attached to the MPE/S will need replacing for each maintenance

cycle. The estimated material cost for batteries requiring replacement over the 3-year MPF

Maintenance Cycle is $729,050 (not including labor).

Consolidated Memorandum Report (CMR) Inventory. The CMR project successfully

demonstrated a significant manhour reduction for conducting a physical inventory through the

application of passive RFID. The time saved to complete Stanley‟s physical inventory of 154

items was 1.28 manhours. Using this manhour reduction as a basis for conducting Blount Island

Command‟s physical CMR inventory, an estimated 54 manhours could be saved with the use of

passive RFID.

Container Load / Mobile Load (CL/ML) Asset Tracking. The CL/ML Asset Tracking project

confirmed that passive RFID applied to the process will reduce the manhours required for the

manual data recording. Using a representative Container Load of 25 items, an average of 19

minutes and 46 seconds (or .329 manhours) was saved by eliminating the need to manually

record all loaded item data. Applying this estimated manhour savings to the MMC-9 MPSron 3

container count; the total estimated savings would exceed 824 manhours.

The manual process of CL/ML data recording is prone to human error. The application of passive

RFID technology to CL/ML provides an automated means of quality control directly impacting the

potential failure point during the physical loading.

Deployable Automated Cargo Measurement System (DACMS) Asset Tracking. Although the

DACMS installation schedule at the permanent Blount Island site did not permit the completion of

this project, the high reliability of asset identification obtained from using the passive RFID

infrastructure for the Ship Backload applies. A subset of the Ship Backloaded tagged equipment

will use the DACMS to determine their weight and dimensions. The infrastructure for the passive

RFID system to include the fixed outdoor readers and antennas is assembled and ready to

integrate once DACMS has been fully installed.


9

1. Systems Integration & Training Facility (SITF)

1.1. Needs Analysis

Methodology approach. The method used to determine the need for a SITF was to

conduct an analysis of the issues encountered during previous attempts to insert new

technology into Blount Island Command‟s business processes. Specifically an analysis of

the problems and limitation of the active RFID implementation was used.

Areas for improvement and problems identified. Blount Island Command was limited in

its ability to integrate and evaluate new products that have the potential of improving their

existing business processes. Specifically, the following limitations were encountered during

the active RFID implementation:

Enclosed Area for System Evaluation and Optimization. The Florida weather is

sometimes very unpredictable and outdoor elements may preclude sustained efforts to

evaluate or optimize a system‟s performance. This was the case when attempting to

characterize the specific behavior and performance of the active RFID Signposts. Having a

controlled indoor area that would not be subjected to wind and rain over an extended period

of time would have allowed multiple evaluations of the system‟s performance for different

configurations. Another example was active RFID tag placement. One of the failure points

of the active RFID was never verifying that the tag placements on different types of

equipment worked effectively. A controlled facility where tags could be applied to military

equipment and tested for optimal readability placement would have eliminated the “best

guess” method.

Information Assurance Certification and Accreditation (C&A). In order to safeguard

from ever-present threats to Defense information technology (IT) assets and information,

the DOD Information Assurance Certification and Accreditation Process (DIACAP) is

required for all information systems. Obtaining certification and accreditation for a

prospective new system that is simply being evaluated can take a considerable amount of

time and effort. Having a dedicated facility with a “Simple or Closed Network” C&A provides

a very flexible environment for test and evaluation.

Indoor Training Facility. Effectively implementing new technology into a modified

business process requires personnel training. A facility where the instruction supports

hands-on use of the new technology promotes highly effective training.

Initial solution requirements determined. The BICmd Passive RFID Charter describes

the objectives for the SITF as follows:

“The SITF will provide the means to evaluate the effectiveness of commercially available

off-the-shelf automated identification technology (AIT) hardware and associated

components. It will provide the means to collect the empirical performance data needed to

substantiate the business case for the AIT application. The facility will support the means

to validate the functional integration and optimize performance of the passive RFID

solutions prior to their final installation. Finally it will provide the means to conduct process

and system user training. Given the continuous improvements being made to passive RFID


10

technologies, the need for this facility is envisioned to continue beyond the duration of this

Charter.”

Success criteria and measures of performance. As specified in the Blount Island

Command Passive RFID Project Charter, the objective for the SITF Project is as follows:

BICmd will have the capability to objectively evaluate commercially available automated identification technology (AIT) products and means to produce measures of effectiveness for their application.

The Measures of Performance are as follows:

Indoor DACMS installation and integration test with MDSS-II Enables the software integration and test of the Fixed Outdoor Portal, the Mobile

Outdoor Portal, and passive RFID Reader Cart prior to final installation. Conduct performance testing of commercially available candidate passive RFID tags

for input to a comparative analysis. The comparative analysis will support the final tag selections to be used on this project.

Conduct passive RFID Tag Placement Optimization for Maritime Prepositioning Equipment and Supplies (MPE/S).

Provide a digital network infrastructure that is physically isolated from the Marine Corps Enterprise Network (MCEN) that will permit the evaluation of AIT products without the need for their Information Assurance (IA) C&A.

1.2. Site Analysis

Solution systems architecture requirements development. Blount Island Command

recognized the value of dedicating an indoor facility to pursue the evaluation of promising

COTs solutions for streamlining business processes. A large available shelter was made

available for this purpose.

ASMB Storage Area

Side Sliding Cargo

Door

16' h 14' 4" w

Side Sliding Cargo

Door

16' h 14' 4" w

90

'

190'

Double

Personnel Door

Double

Personnel Door

Double

Personnel Door

Double

Personnel Door

Main Line Electrical Service

to Shelter – Switch

Alien Portal

Alien Portal

Alien Portal

Alien Portal

DA

CM

S

Sto

rag

e

Tag Performance Test Area

ATM

Navy

Fed

DACMS Laser Profiler

DACMS

Workstation

Mobile Load

Test Area

RF

ID S

tora

ge

Co

nta

ine

r

Mobile Office Trailer

(Office, Conference Room, Computer Room)

12' w x 60' l

Portable Bleachers

(Training and Demonstrations)

MWEN

Savi Signpost

Savi Signpost

Alien Portal

Alien Portal

Alien Portal

47

'3

5'C

on

tain

er

Lo

ad

Te

st

Are

a

DACMS Weight Scale

DACMS

Workstation

BICMD SYSTEMS INTEGRATION

& TRAINING FACILITY (SITF)

4-Port 110v Outlet

Side Ventilation

Fire Extinguisher

Bollard Alien Portal

Savi Signpost

Outdoor Toilet

Figure 1. Systems Integration and Training Facility (SITF) Concept Layout


11

Solution supporting infrastructure requirements

The SITF provided the required enclosed area. It also provided sufficient space for

conducting any number of passive RFID tests required by the different projects. The

minimum infrastructure requirements, such as network ports and power outlets, were

installed throughout the facility.

Figure 2. Blount Island Command Systems Integration and Training Facility

The SITF provides the following features:

1. Modular Office. The Modular Office provides an environmentally controlled

computer room, conference / training room, and office space. It houses the

computer database servers and other information technology systems. The

conference / training room overlooks the indoor facility and accommodates class

sizes of 15 to 20 people.

2. Independent Simple Network. The independent simple network has no interface

with the Marine Corps Enterprise Network (MCEN). This was a critical feature of

the facility, as it avoids the need of having Information Assurance (IA) Certification

and Accreditation (C&A) on candidate solutions prior to being evaluated and

selected for use by the Command.

3. Twenty-foot Equivalent Unit (TEU) Container. The TEU Container provides the

means to validate our passive RFID candidate solutions for tracking military

equipment being loaded to or unloaded from the container. Due to the ever

changing military equipment, packaging materials, and new passive RFID devices,

this fixture provides a convenient means to evaluate possible alternative solutions

and system improvements. Its other function is to serve as a passive RFID training

component for BICmd‟s maintenance contractors.

4. Mock Business Office Cubicles & Equipment. The Office Cubicles & Equipment

provide the means to test and evaluate passive RFID systems as applied to

garrison property (e.g., computers, printers, projectors).


12

5. Training / Demonstration Aids. The SITF provides a host of AV equipment to

include projectors, large displays, public address system, and mobile seating.

6. Mobile Passive RFID Portals. Eight (8) Alien ALX-9010 Portals.

7. Mobile Inventory Module (MIM) Container (Future). The MIM Container consists of

an electrically powered specially designed horizontal carousel that fits and secures

inside a 20 by 8 by 8 1/2 foot, double door, full-side-access container. It contains

fully enclosed bins that travel on a track inside the container. Like the TEU

Container, this will be used for testing and training passive RFID solutions.

Solution supporting hardware requirements

Network Server

Alien ALX-9010 Passive RFID Portals

Closed Network Infrastructure

Solution supporting software requirements

GlobeRanger iMotion

Integrating the Placement and Registration for Identified Material and Equipment

(IPRIME)

SQL Server

MS Visual Studio Developer Licenses

Alien Gateway

1.3. Conclusion and findings. All the objectives for the SITF were met.

SITF Benefits Realized 1. Tag Performance Testing.

a. Commercial Tag Selection. Operational range testing was performed on over 30 different commercially available PRFID tags designed for specific material types. Tag performance test data was captured on over 500 test applications on MPF equipment.

b. Tag Placement Optimization on MPF Equipment / Creation of Tag Placement Guide. The SITF provided the means to conduct the passive tag placement testing on all prepositioning principal end items and containers. The process and system used to conduct this testing is described in Section 2.3. Over 249 principal end items and containers have passed through this facility to identify the optimal tag placement location, and to take associated digital photographs. In addition to identifying locations of the passive tags, the facility also supported the process of collecting digital photographs for the Item Unique Identification (IUID) labels. These digital photographs were loaded to the database to be used for an on-line IPRIME Tag Placement Guide. The IPRIME Tag Placement Guide is a web application that resides on the Marine Corps Prepositioned Information Center (MCPIC). The Placement Guide is also available on the handheld scanners as part of the IPRIME application.


13

2. Passive RFID Demonstrations for BICmd personnel and visitors.

3. Training Conducted. Since its inception, the SITF has been used to train over 70 Blount Island military, civilian and contract personnel in RFID technology and its application to business processes. Classes have been conducted in numerous subject areas to include passive RFID, active RFID, IPRIME, and DACMS. All the training required for the completion of Blount Island‟s Passive Project was performed using the SITF. In addition to the training, the classroom provides the weekly meeting location for Blount Island Command‟s Passive RFID / IUID Working Group.

4. DACMS Integration and Test. The DACMS setup and test was scheduled for January 28-

29, 2009. Approximately 10 representatives from the Marine Corps Systems Command, the Marine Corps Logistics Command – Albany, and the manufacturer traveled to Blount Island

Figure 4. Passive RFID Training for Blount Island Personnel

Figure 3. MCPIC Tag Placement Guide


14

to support its integration with RFID and attend set-up training. The unpredictable Florida weather hit Blount Island with intense rain and wind during these two days, and would have delayed or cancelled the effort. The participants‟ cost of travel and hourly wages for the two days would have been a loss to the government. The SITF‟s enclosed, dry, and spacious test area enabled the team to successfully complete their objectives. Another obstacle that the SITF avoided was the prohibited network communications of the DACMS to the RFID systems due to its lack of IA Certification and Accreditation. The independent simple network infrastructure permitted the requisite communications for all the systems.

The Measures of Performance were as follows:

# Measure of Performance Status

1 Indoor DACMS installation and integration test with MDSS-II.

Complete. DACMS integrated and tested on 28-29 January 2009.

2 Enables the software integration and test of the Fixed Outdoor Portal, the Mobile Outdoor Portal, and passive RFID Reader Cart prior to final installation.

Complete. The Fixed Outdoor Portal and the passive RFID Reader Cart were assembled in the SITF. The Mobile Outdoor Portal was received from Venture Research. Integrated software was developed and tested on each of the systems in the SITF prior to their use.

3 Conduct performance testing of commercially available candidate passive RFID tags for input to a comparative analysis. The comparative analysis will support the final tag selections to be used on this project.

Complete. Performance testing (e.g., range testing) was conducted on passive RFID tags that supported their selection for use on the Ship Backload and the CMR Inventory projects.

4 Conduct passive RFID Tag Placement Optimization for Maritime Prepositioning Equipment and Supplies (MPE/S).

Complete. The software to measure tag read range by location was developed and used on each type of MPE/S. The product output of this was a web-based Passive RFID Tag Placement Guide.

Figure 5. DACMS Integration and Test in SITF


15

5 Provide a digital network infrastructure that is physically isolated from the Marine Corps Enterprise Network (MCEN) that will permit the evaluation of AIT products.

Complete. The SITF provides an installed network that is physically isolated from the base or MCEN. It was used extensively for the integration and test of AIT in support of the passive RFID projects.

Having a dedicated facility for the purpose of evaluating new and improved off-the-shelf solutions

is invaluable. The SITF provides the flexibility to objectively evaluate new products in a

representative IT environment without infusing information assurance risks. Once a new method

or tool is demonstrated to enhance Blount Island‟s business processes and provide a reasonable

return on investment, the SITF provides the means to fully implement the technology by

providing hands-on training to the workforce.


16

2. Ship Backload Operation 2.1. Current Business Process

Process Flow (As-Is). The loading and unloading of Maritime Prepositioning Equipment /

Supplies (MPE/S) to a ship is a recurring process at Blount Island Command. There are

sixteen prepositioning ships that will pass through Blount Island over a three year period.

That equates to approximately five ships a year or one ship every two months. The MPE/S

aboard a specific ship is offloaded and subsequently undergoes an inspection,

refurbishment, or disposal. In addition, new equipment is delivered to Blount Island that is

intended for prepositioning. The MPE/S backload process takes approximately eight

working days. The Ship Backload Asset Tracking process is as follows:

Methods/Tools/System Interface. Two methods were used by Blount Island Command to

identify and track equipment being loaded to or offloaded from a ship.

One method involved an individual using a Symbol 8146 hand scanner to scan a barcode

(PDF417) that uniquely identified the equipment by serial number. The barcode was

printed on a LOGistics application of automated Marking And Reading Symbols

(LOGMARS) label that was affixed to the outside of the equipment. The hand scanners

were brought back to the office each night to export the collected data. Usually there were

two individuals working full-time to perform the barcode scanning for the duration of the

load or unload. This method was abandoned several months ago.

Process Name: Ship Backload Asset Tracking (As-Is)

Establish Ship Master Plan

Of Equipment In MDSS II

Setup Outdoor Active RFID

Signposts (Readers) for

Ramp, Lift-On/Lift-Off

(LOLO), Container Lot

Savi SiteManager monitors

RFID Readers and Records

Equipment‟s Location, Day/

Time Stamp, and Battery

Status

MDSS II / BIC Journal

Periodically Pulls Data From

Savi SiteManager and

Presents Ship Backload

Status


17

Figure 6. Hand Scanner Used to Capture Equipment Data Prior to the Ship Backload

A second method used to identify and track equipment being unloaded from or loaded to a

ship used active RFID technology. Blount Island Command responded to the mandate to

apply active RFID tags to prepositioning equipment in accordance with the USD (AT&L)

Memorandum of 30 July 2004, Radio Frequency Identification (RFID) Policy. By virtue of

this policy, Blount Island Command applied active RFID tags to principal end items (PEIs)

and containers. Additionally, Blount Island Command used the Savi Signposts (SP-652-

211) for establishing location chokepoints to read the active tags. The Signposts use a 123

KHz signal to wake up active RFID tags at an approximate range of twelve feet. In order to

expand the range necessary for equipment moving through a defined “chokepoint”, two of

the Signposts were configured facing each other at a separation of twenty-four feet. Once

the equipment‟s active RFID tag was woken, it transmitted a 433MHz signal that contained

the tag‟s identification, the date/time stamp, the signpost identification it was awoken by,

and the tag‟s battery status. The signpost had a 433MHz receiver that collected this data

and communicated it via a local area network to Savi SiteManager. Savi SiteManager

maintained a tag history database for all the Signpost readers.

The equipment‟s location data is pulled from Savi SiteManager to the Marine Air Ground

Tactical Force (MAGTF) Deployment Support System II (MDSS II).

2.2. Needs Analysis

Methodology approach.

a. Active RFID Analysis. Blount Island Command‟s method of using active RFID

systems for identifying and tracking equipment during the ship‟s offload or backload


18

was evaluated for accuracy and completeness. To determine completeness, the total

tagged inventory was compared to the equipment identified by the active RFID

system.

b. Item Unique Identification Analysis. Concurrently with the passive RFID project,

Blount Island Command had a DoD directive to begin placing Item Unique

Identification (IUID) marks on legacy prepositioning military equipment. The IUID

mark had to comply with the Data Matrix ECC 200 barcode format and contained a

unique item identifier (UII) that distinguished each item. Given the requirement to

assign and apply IUID marks to equipment, Blount Island determined that it would be

cost effective to synergize the IUID marking with the application of passive RFID tags.

Moreover, it was decided that the passive tag would also contain the item‟s UII and

placed in the passive tag‟s extended memory area.

c. Automated Identification Technology (AIT) Cost Analysis. Additionally, the cost

analysis of using active RFID as compared to a passive RFID solution for the purpose

of tracking the MPE/S being loaded to ship was conducted.

Areas for improvement and problems identified. Using the active RFID infrastructure

as described in Section 2.1.2, the identification of all tagged equipment passing through

the chokepoints was found to be incomplete. Data was collected over the course of

multiple ship backloads to determine the percentage of active tags read to the total tags

assigned. The results of this are as follows:


19

Failure causes identified with the active RFID included:

1. Active RFID tags placed on MPE/S are found to have dead or weak batteries. 2. Active RFID tag‟s batteries are found to be improperly installed (backwards

orientation). 3. Improper active RFID tag placement location on equipment

a. No known active RFID tag placement testing was conducted on PEIs to ensure the location‟s readability

b. Despite a Tag Placement Guide, tags were incorrectly placed on PEIs (e.g., Tags affixed to PEIs were found in areas surrounded by metal).

4. Water intrusion into active RFID tag via battery cap disables or triggers failure mode. a. Battery cap not screwed on tight or cross threaded during installation process on

equipment b. Water intrusion causes the tag to short out or triggers failure mode of incessant

transmit 5. Active RFID signposts moved during the backload process that exceeded their range

(>12‟) to wake up and collect a tag‟s data. Despite training and reminders during daily coordination meetings, the signposts continue to be moved by the stevedores rendering the active tag collection improbable or impossible.

Initial solution requirements determined. As described previously, many of the failure

causes of the active RFID system were centered on the tag‟s battery. Naturally a passive

RFID solution that eliminates the need for a battery would remove a significant failure

cause so long as its performance would meet the operational requirements. Furthermore,

the initial procurement cost and the follow-on lifecycle cost of an active RFID tag is very

expensive as compared to other conceivable methods.

1.1.1. Success criteria and measures of performance. As specified in the Blount Island

Command Passive RFID Project Charter, the objective for the Ship Backload Project is as

follows:

Correctly identify passive RFID tagged principle end items prior to the equipment

being rolled on or lifted on to ship and communicate the data. Identify if a tagged

principal end item was loaded via the ship ramp, the crane, or from the Container Lot.


Correctly identify passive RFID tagged principle end items prior to the equipment

being rolled on or lifted on to ship and communicate the data.

Identify if a tagged principal end item was loaded via the ship ramp, the crane (or Lift-

On/Lift-Off (LO/LO)), or from the Container Lot.

2.3. Site Analysis

Site evaluation – Initial Design and Installation Preparation Considerations and

Constraints. Blount Island Command is located on the eastern half of Blount Island in

Duval County, Florida, on the St. Johns River approximately seven miles east of the

Atlantic Ocean shoreline. The pier where the ship backload occurs is subject to all the

harsh environmental effects encountered along the Florida coastline. Duval County has a

humid subtropical climate, with mild weather during winters and hot weather during


20

Ramp

Container

Lot

LOLO

x

x

x

x

x

x

Port Operations

Building

summers. High temperatures average 65 to 92 °F (18-33 °C) throughout the year. It is

common for thunderstorms to erupt during a typical summer afternoon. These are caused

by the rapid heating of the land relative to the water, combined with extremely high

humidity. During winter, there can be hard freezes.

The close proximity of Blount Island Command to the Atlantic Ocean exposes all outdoor

equipment to elevated levels of salt air. Any electrical or electronic equipment used

outdoors for sustained operations must be protected from the corrosive atmosphere.

The system must be capable of alternative power source in the event the AC current is

lost. It is not uncommon to lose power, especially around the pier area.

Process review and identifying passive RFID implementation points. Blount Island

Command had already established the port‟s infrastructure for active RFID implementation

to support the equipment offload or backload tracking. Computer network and electrical

power access points are installed at the pier for active RFID readers.

The Ship Backload has 3 distinct venues that equipment passes as it is being loaded to

the ship. Those venues or chokepoints are: (1) Ship Ramp; (2) Lift-On/Lift-Off (LO/LO) via

crane; and (3) Container Lot Gate entrance to pier.

The Container Lot entrance would support a fixed outdoor passive reader solution on each

side of the gate. However the Ramp and LO/LO chokepoints would have be capable of

being moved when the ship is not loading or unloading.

Solution systems architecture requirements development. Three chokepoints or

passive RFID read points that mirrored those established for the active RFID infrastructure

were required. Each chokepoint would consist of two outdoor readers for a total of six. All

Figure 7. Overview of Blount Island Command Pier and Read Points


21

of the readers would share a network interface with the GlobeRanger server. The

GlobeRanger iMotion platform would serve as the device or reader manager and the ship

backload process manager. It would monitor all outdoor readers and capture all tag read

events. The tag identification would be compared against the ship load plan to determine

status. The critical architectural requirements were as follows:

Outdoor Readers. Outdoor readers are required to setup prior to the backload

and removed when the backload is complete. These outdoor readers would be

used at the Ramp and the LO/LO chokepoints. A permanent read point could be

used for the Container Lot entrance to the pier. They require a wired Ethernet

interface that can interface to a central network switch.

GlobeRanger iMotion Platform. A computer server running the GlobeRanger

iMotion Platform serves as the device manager for all outdoor readers and

monitors health status. The iMotion Platform will also manage the Ship Backload

event workflow and collect all tag read events.

Integrating the Placement and Registration for Identified Material and

Equipment (IPRIME). Facilitates military equipment‟s IUID marking, passive RFID

tag commissioning / placement, and active RFID tag association. It conducts

continuous data quality assurance to ensure equipment data is complete and

correct. It ensures the equipment is registered in the IUID Registry and the USMC

Temporary Datastore (TDS). It provides e-mail notification to the iPRIME

functional mangers in the event any data discrepancies are found for follow-on

resolution. iPRIME resides on a handheld scanner and on a database server.

Data Required for Existing Information Systems. The passive RFID system

would need to integrate with existing information systems used by the MPF

community. Those systems are MDSS II and the BIC Journal. MDSS II is the

standalone system used by Marine Corps Operating Forces to support the tracking

of assets during unit move. The BIC Journal is a web-based intranet application

used by Blount Island Command for keeping a daily written record of experiences

and observations for specific subject areas. The MPS Backload Status is an

application available to the Blount Island Command via the BIC Journal.

Data Required for Existing Information Systems. MDSS II will provide a record

of all principal end items (PEIs) and containers planned for the Ship Backload.

IPRIME will provide a record of the passive tags associated to the PEIs and

containers. As the GlobeRanger iMotion Platform collects the tags read during the

backload it provides an update to an item‟s location code (e.g., Ramp, Container

Lot Gate, or LO/LO) in MDSS II. The BIC Journal, a web-based intranet

application used by Blount Island Command for keeping a daily written record of

events, periodically pulls the Ship Backload item location from MDSS-II and

presents the status of the Ship Backload.


22

Figure 8. Ramp Chokepoint

Figure 9. Lift On/Lift Off (LO/LO) Chokepoint


23

Figure 11. Venture Research Mobile Outdoor Portal

Solution supporting infrastructure requirements. The goal was to leverage as much of

the active system‟s infrastructure as possible for the passive requirements. Given that the

outdoor power and network interfaces were already installed at the pier for each of the

chokepoints (i.e., Ramp, LO/LO, and Container Lot), much of the infrastructure was already

in place. The Port Operations Building provided an indoor location for the server and

workstations.

Solution supporting hardware requirements. The hardware solutions were as follows:

Mobile Outdoor Reader. Both the Ramp and the LO/LO chokepoints required two

each (or four) of the Mobile Outdoor Readers. Refer to Appendix F for a complete Bill

of Material developed to meet this requirement.

Figure 10. Container Lot Chokepoint


24

Figure 12. Fixed Outdoor Passive RFID Components Tested and Ready for Permanent Installation

Permanent Outdoor Reader. The Container Lot Gate entrance would permit 2

permanently installed outdoor readers. A Type 4x NEMA enclosed ALR-9900 reader

was selected and integrated with 2 outdoor Poynting PATCH-A0025 antennas. At the

time of this writing, the permanent pole to mount the NEMA enclosed reader and the

antenna was not yet installed. An industrial outdoor tripod mount served as the

temporary support for this fixed reader assembly.

Solution supporting software requirements.

GlobeRanger iMotion Platform. GlobeRanger iMotion provides communication from

the EDGE (reader, handheld, etc.) to core applications by translating the raw data

coming from the EDGE into IPRIME.

IPRIME. Facilitates military equipment‟s IUID marking, passive RFID tag

commissioning / placement, and active RFID tag association. It conducts continuous

data quality assurance to ensure equipment data is complete and correct. It ensures

the equipment is registered in the IUID Registry and the USMC Temporary Datastore

(TDS). It provides e-mail notification to the iPRIME functional mangers in the event any


25

data discrepancies are found for follow-on resolution. iPRIME resides on a handheld

scanner, personal computer, and on a database server.

MDSS II / BIC Journal. The BIC Journal is a web-based intranet application used by

Blount Island Command for keeping a daily written record of experiences and

observations for specified subject areas. One application available to the Blount Island

Command is the MPS Backload Status. As equipment is being loaded to the ship, the

passive RFID system identifies it and updates its location to MDSS II. The BIC Journal

periodically pulls this data from MDSS II to provide a “near” real-time status of the

backload.

Figure 14. Blount Island Command Journal - Web Application Provides MPS Backload Status

Figure 13. IPRIME System Architecture


26

Tag Type Analysis/Test/Results. See Appendix A.

Conclusion and Findings. Prior to the USNS Pless Backload, the passive RFID tags were

commissioned and applied to the military equipment. The Mobile Outdoor Portals were set

up and configured in the SITF to complete integration and test of the software. The portals

were placed in their respective chokepoints (e.g., Ramp, LO/LO, and Container Lot) and at

the representative widths at each chokepoint. Test vehicles with passive RFID tags were

cycled through the chokepoints to ensure the reader‟s proper function and determine the

reliability of the system‟s ability to capture the tags. A software control loop issue became

apparent (specific only to the outputs of the portal – i.e. siren and light stack). It was

decided that the light stacks and sirens would not be used for the actual ship backload to

prevent any potential confusion for personnel conducting the backload. The system was

configured in a continuous read and collect mode. Subsequent testing of this configuration

resulted in the required reliability to meet the project‟s objectives. (Note: Since that time

Venture Research took the initiative to design, develop and deliver a separate device

control application for use with their Mobile Outdoor Portals.)

Proposed mitigation to constraints. Due to the GlobeRanger‟s software control issues

with the Mobile Outdoor Portal‟s lightstack and siren, all passive readers were configured to

a continuous read and collect mode. The poles were not installed to mount the permanent

outdoor reader components (e.g., Nema enclosed ALR-9900, Poynting Device Antennas)

and two Mobile Outdoor Readers were used in place.

2.4. Proof of Principle Deployment

Supporting Infrastructure deployed. Blount Island Command ensured the electrical

power and network interfaces were in place for the Mobile Outdoor Portals. All network

cable runs were to the Ethernet switch located in the Port Operations Building. The Port

Operations Building also housed the GlobeRanger iMotion Server.

Passive RFID hardware deployed. Venture Research Mobile Outdoor Portal (6) GlobeRanger Server 8-port Ethernet Switch

Software and system architecture implemented. GlobeRanger iMotion Platform


27

2.5. Revised Business Process

Passive RFID Proof of Principle Process Flow. The new business process is as follows:

Passive RFID process integration. No major operational process was changed in the

implementation of the Ship Backload Project. The objective was to measure the reliability

of the passive RFID system to correctly and completely identify the tagged equipment being

loaded to the ship.

Data acquired by the system. MDSS II planned equipment data for the ship backload.

Data provided by the system. Equipment location with day/time stamp.

Data Analysis process and procedure. Out of 706 items with passive tags that passed

through one of the three chokepoints, 660 tags were read and 46 tags were not read.

The final Ship Backload read performance is summarized as follows:

Total Containers Tagged 254

13 5.1%

241 94.9%

Total Principal End Items Tagged 452

33 7.3%

419 92.7%

Overall Tagged Items 706

46 6.5%

660 93.5%

Ship Backload Passive RFID Tag Read Performance

Total Containers Missed

Total Containers Read

Total Principal End Items Missed

Total Principal End Items Read

Total Tagged Items Missed

Total Tagged Items Read

Process Name: Ship Backload Asset Tracking (New)

Establish Ship Master Plan

Of Equipment In MDSS II

Setup Outdoor Passive RFID

Readers for Ramp and

LOLO. Verify Fixed Reader‟s

Operation at Container Lot

GlobeRanger / IPRIME

Manage Readers – Collect

Equipment Identification,

Day/Time Stamp

IPRIME Updates Equipment

Location Data to MDSS II

(BIC Journal)

BIC Journal Presents Ship

Backload Status

* Orange indicates process change


28

Figure 15. D0880 – 1 ½ Ton Trailer 400 Gal Water Tank. Arrow indicates where tag should have been placed in accordance with the placement guide (5 items).

Figure 16. D0860 - Cargo Trailer. Arrow indicates where the tag should have been placed in accordance with the placement guide (11 items).

A failure analysis was conducted on the unread Principal End Item tags. Unfortunately, the

failure analysis was not possible on the unread Container tags due to their inaccessibility

when stowed on the ship. The failure causes for the missed PEI tags are summarized as

follows:

Failure Cause Total

Specified tag location not readable by Portal 5

Training Issue - Tag Identification was Duplicated 3

Training Issue - Tag Not Placed in Accordance with Guide 16

Training Issue - Tag Placed but Not Commissioned 1

Unidentified Failure Cause 7

Vehicle / Tag Missed During Server Reboot 1

Grand Total 33

Ship Backload Missed PEI Tag Reads - Failure

Causes

Figure 17. Dozer Blade. Method of transport in Ship precluded tag read (5 items). Corrective tag location will be validated and updates made to the Tag Placement Guide.


29

Passive RFID Proof of Principle Measures of Performance/Effectiveness.


1 Correctly identify passive RFID tagged principle end items prior to the equipment being rolled on or lifted on to ship and communicate the data.

Complete. The passive RFID system attained a 94% tag identification rate.

2 Identify if a tagged principal end item was loaded via the ship ramp, the crane (LO/LO), or a container coming from the Container Lot.

Complete. Of the 660 tags identified, 419 were identified at the Ramp chokepoint, 113 were identified at the Container Lot chokepoint and 128 were identified at the LO/LO chokepoint.

2.6. Summary and Conclusions.

The passive RFID system had a 94% success rate at correctly and completely identifying the

tagged items being loaded to the USNS Pless. Of the 33 missed tag reads from PEIs, 26 of

them can be corrected either by training or proper tag placement on the PEI. With this said, it is

reasonable to conclude that an equivalent percentage of the 13 missed tag reads on the

containers could also be corrected by training or better tag placement.

Assuming all training issues and tag placements were corrected for PEIs and containers, the

overall projected tag read success rate would be:

The best active RFID performance in identifying tagged equipment during a MPS Backload was

88% (USNS Kocak). The best active RFID performance during a MPS Offload (equipment

removed from the ship) was 77% (MV Bonnyman). The tag read failures associated with

batteries are completely avoided with the use of passive RFID tags. If the intent of Blount Island

Command is to apply RFID technology to accurately count equipment being loaded for billing

calculations, the passive RFID provides a more reliable solution. Data accuracy is critical when

used for this purpose and the passive RFID technology, with proper implementation, can meet

this objective.

Cost to Benefit Analysis. The purpose of the Ship Backload Project was to determine if the

application of passive RFID technology would meet Blount Island Command‟s requirements for

reliably tracking principal end items and containers being loaded to ship. As described earlier,

Total Containers Tagged 254

Adjusted Total Read Provided Corrective Action 246 96.9%

Total Principal End Items Tagged 452


Overall Tagged Items 706



30

the two previous methods used by Blount Island Command included personnel equipped with

barcode scanners and active RFID Signpost readers. The hand-scanning method was found

unreliable and abandoned this past year. The active RFID infrastructure in its current state has

not demonstrated the reliability required to completely and correctly track item during the

backload. Many of the active failure causes centered on the battery that will require periodic

replacement during the tag‟s life-cycle. The passive RFID avoids this failure cause and

associated recurring costs all together. Moreover the cost of the passive tags used for PEIs and

containers in this project is approximately $4 each. Generally, the passive tag suppliers use a

pricing schedule that decreases unit cost with volume orders. The common active tag used by

DoD, Savi ST-654, can cost up to 20 times that of the passive tag. The batteries for the active

tags attached to the MPE/S will need replacing for each maintenance cycle. The estimated

material cost for batteries requiring replacement over the 3-year MPF Maintenance Cycle is

$729,050. Note that this estimate does not include the labor associated with replacing the

batteries and testing the tags.

The passive RFID infrastructure necessary to fully implement a passive solution for the Ship

Backload has been provided through this effort. It utilizes the installed electrical power and

computer networking interfaces at the pier. The only remaining costs to fully implement this

capability are the purchase of the passive tags and their application to the principal end-items.

The effort to commission and apply the passive RFID tags to equipment using IPRIME was

incorporated with the IUID effort. Given Blount Island Command‟s continued requirement and

funded IUID effort for MPF equipment, no additional cost is envisioned to complete the

remaining passive tagging.

It is important to note that the value of applying the passive tags to MPE is not limited to the Ship

Backload. Although it has not been tested yet, it is technically feasible for DACMS to utilize the

passive infrastructure for identifying the equipment prior to it being weighed and measured.

Having passive tagged equipment provides the potential of asset visibility at any point during its

maintenance cycle as long as the reader infrastructure is in place. The passive tags require no

recurring maintenance or consumables during their lifecycle. Physical damage would be about

the only factor that would prevent the tag from functioning as designed. Unlike the active RFID

tags used on MPF equipment, the passive tags have a significantly smaller footprint and are less

susceptible to being struck. It was not uncommon to find active tags on the ground during or

following a MPS backload after being accidently detached in some manner. To further aid in

optimizing a tag design for military use, former military personnel from Blount Island met with

Omni-ID‟s technical staff to provide design recommendations for the tag casing. Dessert Tan and

Olive Green paint samples used on military vehicles were given to Omni-ID to color-match the

tags. Omni-ID implemented the recommended design improvements and colors for their Max-HD

tags that were used in this project.

The risk of physical damage to the tag during operational exposure was mitigated as part of the

tag selection process. Commercially available tags that support an operational temperature

range of –40 to +120 °C (-40 to 248 °F) and have an Ingress Protection (IP) 68 rating (in

accordance with IEC Standard 60529) were selected.


31

2.7. Anticipated next steps.

Complete the installation of two poles to permanently mount the passive readers at the

Container Lot entrance to the pier. A decision is needed regarding the purchase of additional

passive RFID tags to complete the tagging of equipment for MMC-9 MPSron 3.


32

3. Consolidated Memorandum Report (CMR) Inventory

3.1. Current Business Process.

The current CMR Inventory process is manual and paper intensive. No automated identification

technology (AIT) is presently used in the process of conducting a physical inventory.

Process Flow (As-Is): The process is as follows:

Methods/Tools/System Interface. The CMR inventory is maintained in two database

systems of record. Those systems include the Defense Property Accountability System

(DPAS) and the Asset Tracking Logistics and Supply System (ATLASS). DPAS is

administered by the Under Secretary of Defense for Acquisition, Technology, and Logistics

and is a web-based application used by the military branches to provide a common ledger

for the control and reporting of property. ATLASS is the Marine Corps personal computer

based system software program primarily used by the units to order supplies and manage

Table of Equipment (T/E) assets. It produces a data courier file that updates the

Supported Activities Supply System (SASSY). SASSY is the Marine Corps‟s mainframe

system used for supply management, requisitioning, inventory management, and

accounting for T/E assets.

Process Name: CMR Physical Inventory (As Is)

Obtain Previous Quarter‟s

CMR Inventory List & Folder

With Sectional Content of

“Adds/Deletes”, “Moves”, &

“Correspondence”

Reconcile Any

Discrepancies from

Documented Adds, Deletes,

or Moves for Current CMR

Inventory List

Meet with Property Control

Office to Resolve Paper

Discrepancies

Discrepancy?Conduct Physical inventory

– Paper Checklist

Annotate Any Errors with

On-Hand BalancesNo

Yes

Sign, Date, and Submit

CMR Physical Inventory to

the Property Control Office

Property Control Office

Uses DPAS and ATLASS to

Print the Current CMR

Inventory List


33

All of Blount Island Command‟s garrison property is entered and maintained in DPAS with

the exception of the computer and information technology (IT) assets. ATLASS is used to

maintain the inventory accounting for these assets. The reason for using two separate

systems is not important for this report but the manual paper process used to update those

systems is relevant. Any changes to the inventory are hand-entered to DPAS and ATLASS

following the physical inventory from the hardcopy folder.

3.2. Needs Analysis

Methodology approach. An analysis of the current CMR Inventory process was

conducted. The methods and tools used to support the business process were included as

part of the analysis.

Areas for improvement and problems identified. There is no effective use of AIT in the

current business process. The CMR Inventory process is completely manual. The

individual effort to conduct the physical inventory, complete the checklist, identify

discrepancies, and transcribe inventory changes to DPAS and ATLASS is time consuming

and prone to human error.

Initial solution requirements determined. The viability of applying AIT or specifically

passive RFID solutions to assist in the inventory process has been demonstrated in the

commercial industry. The requirements for conducting a CMR inventory would include a

mobile reader solution and a means for assigning / commissioning tags to equipment. Tags

to indicate defined location spaces are also required to be assigned / commissioned.

Figure 18. The CMR Inventory Is Maintained In A Hardcopy Folder


34


Command Passive RFID Project Charter, the objective for the CMR Project is as follows:

BICmd will have measures of effectiveness for the application of passive RFID

technology in the garrison property inventory process.


Decrease manhours required to conduct a physical inventory of all Stanley CMR

assets.

CMR assets and their locations will be correctly identified and reported.

3.3. Site Analysis

Site evaluation – initial design and installation preparation considerations and

constraints. The CMR Inventory for Stanley Associates resides in 3 locations: (1)

Command Building: Office Workspace; (2) Command Building: Information Technology

Room; and (3) Systems Integration and Training Facility. Given a relatively large area to

conduct the inventory, a mobile passive RFID read method is needed that operates in a

stand-alone mode while conducting the physical inventory. A secure wireless network

interface is not currently available. The mobile solution must also provide for its own

electrical power.

Process review and identifying passive RFID implementation points. The CMR

Inventory process requires the operator to move to each of the equipment locations to verify

the equipment‟s placement. A mobile passive RFID Reader Cart or a handheld passive

RFID reader is required. The CMR inventory data would be downloaded to the mobile

computer via a wired Ethernet or IEEE 802.11g wireless connection to the IPRIME

database. Each location where inventory items reside would have a fixed passive tag that

designates the specific location. This “location” tag will associate inventoried items to that

specific location.

Solution systems architecture requirements development. The IPRIME-CMR system

contains the database of all property assets. The software supports a combination of hand

held passive RFID readers and passive RFID enabled carts to commission passive RFID

tags for items. IPRIME-CMR also creates the “location tag” for specified areas where

property assets reside. Finally, IPRIME-CMR software is used on the passive RFID

enabled devices to scan the passive tags associated to the items on their CMR and

associate the location of those items.

Solution supporting infrastructure requirements. The mobile passive RFID reading

devices use rechargeable batteries to provide power. They can be connected to the

building‟s electrical power at night or when not in operation for battery charging. Ethernet

network connectivity is provided throughout the facility. Note: The Blount Island Command

building does not currently support secure wireless networking. Consequently, the passive

reader devices use a wired network interface to retrieve and download data to the IPRIME

database.


35

Solution supporting hardware requirements. IPRIME-CMR Server Intermec CK61 hand scanner and IP30 Reader

Battery Pack, CK60 Single Dock, CK60 Ethernet/USB Secure Digital Card, 2.0GB Charger, 2-bay, SR61/IP30

Reader Cart Alien ALR-9900 Reader 3-Circular Passive Antennas Laptop Computer w/Ethernet port 2-volt DC battery 300Watt Power Inverter R/G/B Lightstack


IPRIME – SQL Server IPRIME – CMR application for CK61/IP30 IPRIME – CMR application for Mobile Reader Cart


Conclusion and findings. All of Stanley‟s CMR inventory assets were tagged with the

RCD Sentry. They were commissioned using IPRIME-CMR software and used EPC DoD-

96 data format for the tag identification. The site-location tags were commissioned and

placed in the designated areas where the inventory resides. Both the manual method and

the passive RFID methods were used to conduct the physical inventory. The time required

for each method was recorded.

Figure 19. RCD Technologies Sentry-M Passive Tag

Proposed mitigation to constraints. The Blount Island Command is currently in the

process of obtaining Certification and Accreditation (C&A) to implement a secure wireless

network.

3.4. Proof of Principle Deployment

Supporting Infrastructure Deployed.

Battery charge stations / AC Electrical Power Ethernet network ports


36

Figure 20. Mobile Passive RFID Reader Cart

Passive RFID Hardware Deployed. IPRIME-CMR Server Intermec CK61 hand scanner and IP30 Reader

Battery Pack, CK60 Single Dock, CK60 Ethernet/USB Secure Digital Card, 2.0GB Charger, 2 bay, SR61/IP30

Reader Cart ALR-9900 3-Circular Passive Antennas Laptop Computer w/Ethernet port 12-volt DC battery 300Watt Power Inverter R/G/B Lightstack


37

Software and system architecture implemented IPRIME – SQL Server IPRIME – CMR application for CK61/IP30 IPRIME – CMR application for Mobile Reader Cart

3.5. Revised Business Process

Passive RFID Proof of Principle Process Flow. The revised business process is as

follows:

Figure 21. IPRIME System Architecture


38

Passive RFID process integration. IPRIME-CMR training was conducted using the new

passive RFID process and reader methods.

Data acquired by the system. Current import of the CMR Inventory items data on record

from DPAS and ATLASS.

Data provided by the system. Current export of all CMR Inventoried items. This includes

all item “Adds”, “Deletes”, and location updates.

Data analysis process and procedure. Stanley conducted the physical CMR Inventory

using the “As-Is” manual method and the “New” passive RFID method. A stopwatch

captured the time taken to complete each of these methods. The process included only the

effort to complete the inventory. The times captured do not reflect the barcode labeling

(Manual Method) or the passive tag application to the items. The labeling or tagging of

inventoried items is a one-time event whereas the physical inventory is conducted on a

recurring basis. The times taken to complete each method are as follows:

Process Name: CMR Physical Inventory (New)

Download Physical

Inventory Data from iPRIME

to Mobile pRFID Reader

Conduct Physical Inventory

Using Mobile Reader

Electronically Reconcile Any

Asset Adds or Deletes With

Locations

Electronically Submit

Discrepancies to Property

Control Office to Review /

Approve

Discrepancy?

Print, Sign, Date, and

Submit Physical Inventory

List to Property Control

Office

No

Yes



39

Stanley Associates Physical Inventory Times

Manual Method

Passive RFID Method

Inventory Location Time (h:mm) Time (h:mm)

Systems Integration & Training Facility 0:32 0:06

Stanley Office (Bldg. 100) 0:50 0:05

Classroom 0:07 0:01

Total Time 1:29 0:12

Stanley‟s inventory consists of 154 items. The total time saved using the Passive RFID

Method was 1 hour 17 minutes or 1.28 manhours.

PASSIVE RFID Proof of Principle Measures of Performance/Effectiveness.


1 Decrease manhours required to conduct a physical inventory of all Stanley CMR. The CMR assets and their locations will be correctly identified and reported.

Complete. The time required to complete the inventory was reduced by 1.28 manhours. All inventory items were correctly and completely identified.


The time saved to complete the Stanley‟s physical inventory of 153 items was 1.28 manhours.

The manhours to complete the physical inventory are summarized as follows:

Total Inventory

Count

Manual Method Manhours / Item

IPRIME – CMR PASSIVE RFID

Method Manhours / Item

Stanley Inventory 153 0.0097 0.0013

If you apply these manhour estimates to completing Blount Island‟s physical inventory, the

manhours are summarized as follows:

Blount Island Command’s Inventory (As of 18 August 2009)

DODAAC Item Count Manual Manhours

Required

PASSIVE RFID Manhours Required

Manhour Savings Delta

M38450 657 6.37 0.86 -5.51

M67659 601 5.83 0.79 -5.04

M92502 5232 50.72 6.84 -43.88

Total 6490 62.92 8.48 -54.44


40

Consequently, for each complete physical inventory conducted by Blount Island Command, an

estimated 54 manhours could be saved. Note that this estimated savings does not take into

account Blount Island Command‟s large geographically area with multiple locations and account

managers. Consequently it is fair to conclude that the estimated 54 manhour savings is on the

low end.


Continue research into providing an automated data interface with the Marine Corps systems

used for managing CMR inventory data. These systems include ATLASS and DPAS.

Implement the secure wireless network capability once it has completed its Certification and

Accreditation for Blount Island Command.


41

4. Container Load / Mobile Load (CL/ML) 4.1. Current Business Process

Process Flow (As-Is). The As-Is business process is as follows:

Process Name: Container/Mobile Load Asset Accounting (As-Is)

Container / Vehicle Is

Positioned For Loading and

MPE/S Is Staged in

Warehouse

Shipping Personnel

Manually Record Container /

Vehicle Serial Number on

Paper Form

Shipping Personnel Reads

Item‟s LOGMARS Label and

Writes NSN and Serial

Number on Form.

Item Is Packed in

Container / Vehicle

Container /

Vehicle

Complete?

No

Container / Vehicle is

Closed and SealedYes

Form Is Provided to

Adminstrative Staff to

Manually Enter Data Into

MDSS II

Methods/Tools/System Interface. The method of accounting for inventory loaded to

containers or mobile loads is manual. All inventory data for loaded items to a container or

vehicle is written down and at the completion of the load, entered into MDSS II.

4.2. Needs Analysis

Methodology approach. A site survey was conducted at Blount Island Command to

analyze the current CL/ML business process.

Areas for improvement and problems identified. The method used to account for items

loaded to a container or vehicle is manual. The shipping clerk records the container or

vehicle‟s serial number on the form and then writes each item‟s serial number being loaded

on the form. Once the load is complete, the container or vehicle is sealed and the inventory

list is turned over to a data clerk to enter the data into MDSS II. This method of accounting

is man-hour intensive and subject to human error. The only automated tool currently used

by Blount Island Command to provide CL/ML data quality is Quality Assurance Tools (QA

Tools). QA Tools provides a detailed load plan validation with the item records in MDSS II.

QA Tools only provides a data QA reconciliation process; no physical QA process is

available. As a supplement to QA Tools, significant process efficiency would be achieved

by implementing a method to instantly notify the equipment loader of any discrepancies

between the load plan and equipment being loaded.

Initial solution requirements determined. A simple solution of using AIT as a means to

identify the specific container or vehicle (“parent”) and the items (“children”) loaded was

required. This would alleviate the man-hour burden of manually writing the information on

the form while reducing the risk of data entry error.

Anticipated success criteria and measures of performance. As specified in the Blount

Island Command Passive RFID Project Charter, the objective for the CL/ML Project is as

follows:


42

BICmd will have effectiveness measures for the application of passive RFID technology

in the Container Load and Mobile Load (CL/ML) data collection process.


Correctly identify and communicate the data on passive RFID tagged MPE/S prior to

being loaded to a mobile loaded vehicle or into a container.

4.3. Site Analysis

Process review and identifying passive RFID implementation points. As stated, a site

survey was conducted for the CL/ML processing. It was noted that multiple containers and

vehicles are staged simultaneously for loading items. It was also noted that the shipping

clerks use “trial and error” to fit items and to optimize the space usage. For example, it is

not uncommon for items to be removed from one container and placed in another to

maximize the space usage. As items are moved to other locations, the accounting list is

manually updated with the changes. Therefore, the passive RFID solution must take into

account the process of items being loaded and unloaded to the container.

In order to cover a wide number of vehicles or containers being loaded simultaneously,

passive RFID readers must be positioned at each location. Moreover, the container loads

are completed outdoors while the mobile loads are completed indoors.

Solution systems architecture requirements identification. The passive RFID readers

must be mobile. As containers are filled and closed, the readers must be capable of

moving to another container or vehicle.

Solution supporting infrastructure identification. To support the mobile readers, a

secure wireless network infrastructure is required to communicate the inventory data to

IPRIME. The Marine Corps has adopted Air Fortress to fulfill this purpose; it has not,

however, been fully implemented at Blount Island. Moreover, Blount Island Command is in

the process of obtaining the Certification and Accreditation (C&A) for Air Fortress.

Therefore, the mobile readers must be functionally capable in a non-networked mode.

Similarly, electrical power is needed for the mobile readers and processor. These solutions

must be capable of supplying their own power for the duration of the workday (e.g., 8

hours). When the container or mobile loaded vehicle is completed, or at the end of the work

day, the data from the mobile reader must be uploaded to IPRIME via a wired method.

Solution supporting hardware identification. Passive RFID Reader with Antennas - mounted to a mobile stand

Laptop computer – processing CL/ML application within IPRIME

32” Outdoor Display – mounted to mobile stand with video cable to laptop computer

Computer network Ethernet Port – Communicating CL/ML data between mobile reader

and IPRIME server


43

Solution supporting software identification. IPRIME – CL/ML Application

MDSS II

Tag Type Analysis/Test/Results. The passive RFID tags used for this application were the

LOGMARS label with the embedded Alien Higgs 3 squiggle. See Appendix A.

Conclusion and findings. IPRIME-CL/ML was used with the passive RFID to load a

container with a representative set of items (See Appendix C). The time required to load

the container, correctly identify the items and enter the data to the system was recorded.

No data errors were encountered when identifying the “parent” container serial number or

specific items loaded to the container.

The value of the passive system is measured in two ways. First, the passive system

provided a means of automating quality control into the loading process directly at the

instant of failure. The “parent” container or vehicle was correctly identified and the items

loaded were checked against a load plan. The detailed load plan is maintained in the

Prepositioned Planning System (PPS) and is available on the Marine Corps Prepositioning

Information Center (MCPIC) intranet site.

Figure 23. MCPIC - Prepositioning Planning System

Figure 22. Container Load Passive RFID Infrastructure


44

Any errors encountered such as the loading of too many of a particular item or loading the

wrong item were prevented. The second value was in the replacement of the manual

process of recording the actual loaded inventories. Writing the parent container or vehicle

on paper along with each of the items that was loaded was eliminated. Moreover the

process of manually keypunching the inventory data from the paper form into MDSS II was

replaced.

To estimate the manhours saved using the former manual method, the time was captured

to load the container, write each of the items on the form, and keypunch the items into

MDSS II. This time trial was conducted twice to gain confidence into the manhour savings

that could be realized using the automated passive RFID method. Two consecutive test

trials of loading the container and recording the items were performed; the average

manhour savings are outlined below:

Container Load Time Trial Time (mm:ss)

1 Manual Container Load – Hand written inventory

09:46

2 Manual Data Entry to MDSS II 10:00

19:46

Using 19:46 as an average time savings per container, the total manhour savings per

container would be 0.329 manhours. Applying .329 manhour savings per container to the

MMC-9 MPSron 3 container count, the total estimated savings would be:

MPSRON-3 Planned Container Count

LUMMUS PLESS WILLIAMS MARTIN DAHL Total

542 518 531 484 429 2504

Total Containers

Manhour Savings / Container

Total Manhour Savings

2504 0.329 824.93

The estimated total manhour savings equates to approximately 825 manhours for MMC-9

MPSron 3. In addition to the estimated manhour savings, the real intrinsic value of applying

passive RFID is quality control. The passive RFID minimizes the possibility for human error

in a very manually intensive process. It provides an automated means to ensure that the

right items and quantities are loaded to containers or mobile loads.

Proposed mitigation to constraints. Due to the number of containers and vehicles that

are loaded simultaneously, project funding limitations would not permit the complete

implementation of a passive RFID system solution for CL/ML. Consequently, the

demonstration was performed in the SITF using a HMMWV and a Container with

representative item loads.


45

Figure 24. Container Load – Passive RFID System Validates Loaded Items To Plan and Provides Real-Time Feedback to Personnel Indicating Any Required Corrective Action

Figure 25. A Mobile Loaded HMMWV Utilizes Passive RFID To Identify The Vehicle’s Serial Number Then Prepares to Capture and Associate Tagged Items During the Load Process

4.4. Proof of Principle Demonstration Deployment

Software and system architecture implemented. Passive RFID Reader with Antennas - mounted to a mobile stand Laptop computer – processing IPRIME-CL/ML application 32” Outdoor Display – mounted to mobile stand with video cable to laptop computer Computer network Ethernet Port – Communicating CL/ML data between mobile reader and IPRIME server

Proof of Principal Demonstration. A representative Container Load and Vehicle load of items was selected. This list can be found in Appendix C. The IPRIME CL/ML application identified the “parent” by reading the serial number from a passive tag attached to the container or vehicle. Once the parent was confirmed, the items were loaded into the container or vehicle. As items were identified, IPRIME CL/ML verified the items in the Load Plan. Any identified items that did not conform to the Load Plan were highlighted in “Red” on the display.


46

Figure 27. Following Completion of the Mobile Load, the Passive RFID System Has Captured a Complete Inventory of Loaded Items and Associated Them to the Truck

Figure 26. IPRIME-CL/ML Validates The Item Load To The Plan And Provides Real-Time Confirmation Or Corrective Action Required


47

4.5. Anticipated Revised Business Process

Passive RFID Proof of Principle Process Flow. The New business process is as follows:

Passive RFID process integration. IPRIME-ML/CL system training was performed using

the new process and reader method.

Data to be acquired by the system. IPRIME –ML/CL downloads the Container and

Vehicle load plans from the Prepositioned Planning System (PPS). The PPS maintains the

detailed account of items and their quantities to be loaded in a container or a vehicle

(mobile load).

Data to be provided by the system. Complete item inventory data loaded to container or

vehicle. Discrepancy data of items that were not loaded in accordance to plan or items

loaded that should not have been.

Passive RFID Proof of principle measures of Performance/Effectiveness.


1 Correctly identify and communicate the data on passive RFID tagged MPE/S prior to being loaded to a mobile loaded vehicle or into a container.

Complete.

Process Name: Container/Mobile Load Asset Accounting (New)

Container / Vehicle Is

Positioned For Loading and

MPE/S Is Staged in

Warehouse

Mobile Passive RFID

Reader Infrastructure is

Positioned Next to

Container / Vehicle

IPRIME Monitors/Controls

Passive Reader. Passive

Reader Identifies “Parent”

Container / Vehicle

IPRIME Presents

Container / Vehicle ID to

Outdoor Display For

Verification

Container /

Vehicle Full?Container / Vehicle is

Closed and SealedYes

IPRIME Sends Container /

Vehicle Inventory Data to

MDSS II

IPRIME Is Loaded with

Container / Vehicle Load

Plan(s) – Item Data (e.g.,

NSN, Serial Number)

Shipping Personnel Loads

Tagged Item Into

Container / Vehicle

IPRIME Identifies Item and

Verifies Load Plan

Load Plan

Verified?

IPRIME Presents

Information to Shipping

Personnel for Resolution

Shipping Personnel Accept

Change to Plan or Remove

Incorrect Loaded Item

Yes

No

No



48


The two primary benefits achieved from implementing passive RFID into the CL/ML are in the

reduction of manhours that would replace the manual process of data recording and the increase

of quality control. The manual process is prone to human error during the item recording to a

form and the data entry into MDSS II. The second benefit is inserting an automated means of

quality control at the potential failure point. This application provides the shipping personnel

instant feedback as to items erroneously being loaded in accordance with the detailed load

plans.


Expand the CL/ML application to the Blount Island Command‟s Communications Security

(COMSEC) Material System (CMS). Establish the infrastructure for tracking the placement or

removal of COMSEC equipment in the secured containers.


49

5. Deployable Automated Cargo Measurement System (DACMS) 5.1. Current Business Process

Process Flow (As-Is). All filled containers and mobile-loaded vehicles must be weighed at

the scale house. This data is used by the embarkation team to ensure proper weight

distribution throughout the ship.

Figure 28. Container Truck Entering Weight Scale

The current process is as follows:

Methods/Tools/System Interface. The current process of weighing a container or mobile-

loaded vehicle and recording the data is manual. The scale house attendant uniquely

identifies the equipment, weighs it, and hand enters the item weight into MDSS II.

This past year, the Marine Corps Systems Command purchased and delivered the DACMS

to Blount Island Command to supplant the existing scale house process. In addition to

providing the weight, the DACMS uses a laser profiler to provide the item‟s dimensional

characteristics. Furthermore, the DACMS was developed with an automated data interface

with the Savi active RFID Signpost and MDSS II. The Signpost uniquely identifies the

tagged item and communicates this to MDSS II. MDSS II provides the item data to

DACMS. DACMS weighs and measure the item, and then populates MDSS II. This

interface was demonstrated at Blount Island during setup training conducted in the SITF on

28-29 January 2009 (See Section 1.3). The use of the DACMS has been put on hold to

Process Name: Weigh and Record Containers & Mobile Loaded Vehicles (As Is)

Scale House Attendent

Uniquely Identifies a

Container or Mobile Loaded

Vehicle

Container or Vehicle Is

Moved On Scales and

Weight Tape Is Produced

Attendant Manually Enters

Item‟s Weight to MDSS II


50

allow for the permanent installation of the weight scales. Additionally, an updated release

of MDSS II (version 7.3) provides an improved interface with DACMS.

5.2. Needs Analysis

Methodology approach. The approach applied to the DACMS project was to analyze the

automated interface with the active RFID system and determine the feasibility of

substituting that system with a lower cost and a more highly reliable solution.

Areas for improvement and problems identified. The current plan for uniquely

identifying equipment and communicating it to DACMS uses an active RFID solution. In

fact, DACMS uses the exact same RFID infrastructure as described in the Ship Backload

Project and is subject to the same problems (described in Section 2.2). The areas of

improvement for this project include increasing reliability of the AIT solution and

substantially lowering the implementation cost.

Initial solution requirements determined. The automated interface between the active

RFID system and MDSS II / DACMS has been demonstrated. Since the complete DACMS

installation at Blount Island Command has been delayed until later this year, the

requirement for this project is to leverage the empirical data acquired from the Ship

Backload Project to substantiate the active RFID system replacement with passive.

Figure 29. Deployable Automated Cargo Measurement System (DACMS)


51


Command Passive RFID Project Charter, the objective for the DACMS Project is as

follows:

BICmd will have the analysis that depicts the application of passive RFID technology as

a reliable and cost effective means for automatically identifying equipment and

communicating that information with the Deployable Automated Cargo Measurement

System (DACMS) for data entry to MDSS II.


Analysis to conclude that the passive RFID tagged principle end item’s data would be

correctly communicated to DACMS to be associated with its weight and measurement.

5.3. Site Analysis

Site evaluation – initial design and installation preparation considerations and

constraints. The permanent DACMS installation is underway. A concrete pad has been

installed along with the DACMS outdoor components (e.g., laser profiler). The concrete

pad is 20‟ wide. A bollard protected area resides on each side of the concrete pad

entrance for the RFID readers / antennas. A pole at each protected area will be installed

for mounting the NEMA enclosed readers and outdoor antennas. The width between the

poles is 24‟. The outdoor electrical power and network interface ports have already been

installed in these areas.

Process review and identifying passive RFID implementation points. The passive

RFID will be implemented in place of the active RFID system.

Solution systems architecture requirements development. A permanent passive RFID

infrastructure is required for this application. As noted in Section 2.3.1, the infrastructure

would need to survive the environmental exposure at this location. The IPRIME, MDSS II,

passive RFID readers, and the DACMS computer system require a network interface.

New DACMS (Weigh-In-Motion) Site

1. Two poles are required for mounting RFID readers with antennas at the DACMS site.

2. Each pole shall be aligned between the two bollards facing the concrete pad on each side (as depicted).

3. The poles shall be 2.5” in diameter and 8’ tall from ground level.

4. The poles shall have corrosion protection.

Figure 30. New Permanent DACMS Installation Site


52

Figure 31. Fixed Passive RFID Components Ready for DACMS Installation

Solution supporting infrastructure requirements. A 2” diameter by 12‟ tall pole is

required for mounting the RFID hardware on each side of the entrance to the concrete pad.

Electrical power and a computer network interface are already installed on each side.

Solution supporting hardware requirements.

(2) permanently mounted NEMA 4x enclosures containing Alien ALR-9900 readers and

associated power supplies (1 per side)

(4) Poynting Antennas – PATCH-A0025 (2 per side)

(2) Motion sensors (1 per side)

One Red/Yellow/Green Light Stack (Left side)


IPRIME

MDSS II

GlobeRanger iMotion Platform



53

Conclusion and findings. As noted, the infrastructure to support the permanent outdoor

readers and antennas is partially in place. The NEMA enclosed readers and outdoor

antennas have been procured and are available and waiting for the installation of mounting

poles. Note that these poles are not pacing the completion of this project since the

permanent weight scales are not scheduled for installation until later this year. Although the

DACMS interface was not fully demonstrated, it is fair to conclude that the reliable

identification of vehicles and containers by the passive RFID system from the Ship

Backload project lends confidence that the passive RFID systems design approach for

DACMS will be successful.

Proposed mitigation to constraints. Blount Island Command will complete the DACMS

installation later this year. The integration of the passive RFID system is low risk. Once the

installation is complete, the system will undergo a final integration and test.

5.4. Anticipated Revised Business Process

Passive RFID Proof of Principle Process Flow. The New business process is as follows:

Process Name: Weigh and Record Containers & Mobile Loaded Vehicles (New)

Vehicle Is Moved to DACMS

Entrance – Encounters Red

Light at Passive Read Point

Passive RFID System

Identifies Equipment and

Communicates With IPRIME

Equipment is moved

through Laser Profiler and

Scales

IPRIME

1. Verifies Equipment

Identification

2. Communicates Equipment

Identificaiton to DACMS

3. Turns Green Light On

DACMS System

Communicates Vehicle

Dimensions and Weight to

IPRIME

IPRIME Communicates

Equipment Dimensions and

Weight to MDSS II


Passive RFID Process Integration. From the operator perspective, the passive RFID

process will be the same as the active RFID with the exception of the Red/Green light

indications. Visual feedback to the vehicle operator is not provided by the active RFID

system.

Data to be acquired by the system. Vehicle or container data record verification.

Data to be provided by the system. Vehicle dimensions, center of mass, and weight.

Data Analysis process and procedure. N/A


54

Passive RFID Proof of Principle Measures of Performance/Effectiveness.


1 Analysis to conclude that the passive RFID tagged principle end item‟s data would be correctly communicated to DACMS to be associated with its weight and measurement.

Complete. By similarity to the Ship Backload performance and the successful integration with the active RFID Signpost.


The high reliability of asset identification obtained from using the passive RFID infrastructure for

the Ship Backload applies to the DACMS. A subset of the Ship Backloaded items will use the

DACMS to determine their weight and dimensions. Those items requiring the DACMS

measurements include containers and mobile loaded vehicles. The infrastructure for the passive

RFID system is ready to integrate once DACMS has been fully installed.


Complete the installation of the DACMS scale

Complete the installation of the mounting poles for the passive RFID infrastructure

Complete the installation of the permanent passive RFID system

Perform integration and testing of the hardware and software

Go live

6. Appendices

Appendix A Passive RFID Tag Testing

Appendix B Acronym Listing

Appendix C Container Load / Mobile Load Representative Item Listing

Appendix D Letter of Intent

Appendix E Blount Island Command Passive RFID Charter


A-1

Appendix A - Passive RFID Tag Testing

Blount Island Command conducted operational range testing on over 30 different commercially available

passive RFID tags. The candidate tags were selected for specific material types with an emphasis on

metal surface. The tag‟s range performance data was collected on over 500 military equipment

applications. Additional testing using a select group of tags was also conducted by Alien Technology at

their RFID Solutions Center and at their corporate headquarters in Morgan Hill, CA.

A candidate list of commercially available passive RFID tags was compiled that depicted its intended

surface material, durability, memory capacity, and size. Sample tags were requested and provided by

the vendors for performance testing.

Passive RFID Tag Test software was developed by Blount Island Command to methodically capture the

read range performance (e.g., read count) of a candidate tag at predefined distances, attenuation levels,

and angles to the passive RFID reader. The software auto-generated test cases for a given tag at each

of the parameters mentioned. The software provided the tester step-by-step instruction to complete the

test cases. In addition the software captured a photograph of each test instance from the reader‟s

perspective.


A-2

Hummer Rear Vehicle Test Results

Alien

Front Web

Confidex

Survivor

Confidex

Halo

Confidex

Ironside

Omni-ID

White Brick

Listed below are the top 5 performing pRFID Tags. The test was conducted by placing each pRFID tag on the Hummer, then read counts were sampled at 3 second intervals for each power level of the pRFID

interrogator (1000 - 32 mW at the interrogator) across 3, 6, 9, 12 and 15 foot distances and 0º, 45º and 315º rotations for each distance. Performance is determined by the total read count of the tag across all

distances and rotations. The best performing tag is on the left and the poorest is on the right. Tags whose performance is not in the top 5 are not listed below.

Integrated Chip: Alien Higgs-3

Length: 3.9'‟

Width: .475'‟

Height: .480'‟

Ingress Protection: N/A

Operating Temperature: N/A

Integrated Chip: NXP UCODE G2XM

Length: 2.03'‟

Width: 1.87'‟

Height: 0.39'‟

Ingress Protection: IP68

Operating Temperature: -40ºF to +185ºF


Length: 2.36'‟

Width: 0.47'‟

Height: 0.55'‟




Length: 8.8'‟

Width: 0.94'‟

Height: 0.31'‟



Integrated Chip: Alien Higgs-3

Length: 4.1875"

Width: 2.3125"

Height: .375"


Operating Temperature: -4ºF to +159.8ºF

`

Distance Rotation Max 75% 50% 25% Min Total0º 9 9 10 10 10

45º 9 9 9 10 10

315º 10 9 9 9 10

0º 9 9 10 9 10

45º 0 0 0 1 0

315º 9 9 9 9 9

0º 10 8 9 8 9

45º 0 0 0 0 0

315º 3 4 2 2 3

0º 3 0 1 1 0

45º 0 0 0 0 0

315º 0 0 0 0 0

0º 0 0 0 0 0

45º 0 0 0 0 0

315º 0 0 0 0 0

Total 62 57 59 59 61 298

POWER

3' 142

6' 93

9' 58

12' 5

15' 0


45º 9 10 10 10 9

315º 9 10 10 10 11

0º 10 10 10 9 9

45º 10 9 10 10 10

315º 10 9 10 10 10

0º 9 10 10 10 9

45º 10 11 9 10 10

315º 11 10 10 9 10

0º 9 10 10 10 9

45º 6 19 13 13 9

315º 9 9 9 9 10

0º 9 10 11 10 9

45º 0 0 0 0 0

315º 13 8 15 11 8

Total 134 150 151 142 134 711

POWER

3' 159

6' 146

9' 148

12' 154

15' 104


45º 11 10 10 11 10

315º 10 10 9 8 10

0º 10 10 9 10 9

45º 9 7 14 10 8

315º 10 10 10 9 9

0º 10 10 11 10 9

45º 0 0 0 0 0

315º 12 15 11 7 15

0º 15 13 21 11 14

45º 0 0 0 0 0

315º 7 2 0 0 0

0º 5 6 10 5 10

45º 0 0 0 0 0

315º 0 0 0 0 0

Total 109 102 116 91 104 522

3'

6'

9'

12'

15'

149

144

110

83

36

POWER


45º 10 11 10 10 10

315º 9 10 11 10 9

0º 10 10 10 10 10

45º 10 10 10 11 10

315º 3 5 17 6 8

0º 10 10 10 10 10

45º 9 11 10 10 10

315º 0 0 0 0 0

0º 9 8 8 6 10

45º 10 10 21 10 10

315º 0 0 0 0 0

0º 6 4 7 5 8

45º 0 0 0 0 0

315º 0 0 0 0 0

Total 96 99 125 97 104 521

POWER

3' 149

6' 140

9' 100

12' 102

15' 30


45º 90 93 96 93 93

315º 85 82 86 79 85

0º 91 94 90 87 88

45º 90 90 96 95 90

315º 30 21 26 30 11

0º 80 87 71 86 85

45º 89 90 89 88 88

315º 5 3 1 5 5

0º 74 76 68 65 78

45º 86 85 78 92 82

315º 0 0 0 0 0

0º 37 39 37 47 38

45º 36 43 30 39 38

315º 0 0 0 0 0

Total 883 899 864 899 871 4416

9' 872

12' 784

15' 384

POWER

3' 1347

6' 1029

0

20

40

60

80

1001

23

Read Counts vs Rotations

3''

6''

9''

12''

15''

The results of the test data produced the following tag comparison chart:

3 FT

6 FT

9 FT

12 FT

15 FT

The Passive RFID Tag Test Procedures

1. A Tag Test Analysis was defined. It consisted of a preselected set of candidate tags and the equipment to which they would be attached (e.g.,

HMMWV, Tug, and Water Can).

2. The Tester selected the distances and angles required for the test.

3. The Tag Test software would auto-generate the test cases for each each tag, at each distance, and at each angle.

4. The Tester moved the mobile passive reader to the locatoin (as indicated by the software).

5. For each passive RFID tag in the analysis, a tag read count was collected for 3 second duration at incremental attenuation levels. The software

also captured a photo of the tag on the equipment from the perspective of the reader. The Tester would replace the tag with the next test tag

and repeat the test until that location was complete.

6. The Tag Test software instructed the Tester to move the reader to the next defined location and repeat the test.


A-3

Several trade variables were used for tag selection for each of the Blount Island Command passive RFID

projects. Those variables included: (1) Maximum Read Range; (2) Durability; (3) Estimated Cost; (4)

Extended Memory Capacity; (5) Footprint; and (6) Vendor Capability. The tag‟s range performance was a

critical trade variable in their selection for all the Blount Island Command projects.

Ship Backload and DACMS Projects

Tag Requirements

The MPE/S tagged for this application were primarily large vehicles, containers, and other metal surface

assets such as generators and trailers. They had a much larger surface area for tag placement. A

consistent read range of 15 feet was required. Tags were also required to have 512 bit extended user

memory. This extended memory was used to store the Unique Item Identification (UII). Depth of the form

factor was also a consideration to ensure survivability in certain environments.

Tests Performed

The primary test performed was „on metal read range‟ to determine if the tags would meet the range

requirement. All the tags above met the 15 feet read range requirement as identified by previous testing

at Blount Island, and at the RSC, so a further criteria of read count was also evaluated. To further

determine the differing strength of tags, the following EPC accredited test method was used at the EPC

accredited RFID Solutions Center test lab in Dayton Ohio.

The read range of passive RFID tags is determined by the communication path between the reader and

the tags. The communication path consists of the forward link, the link from the reader to tag, and the

return link, the link from the tag back to the reader. A passive tag does not contain its own power source

but instead converts RF energy received from the reader and antenna system in the forward link into

power. The tag reply to the reader (return link) is by means of modulated backscatter. The tag modulates

its data onto the remaining energy; the energy not utilized in powering the tag‟s circuits, from the forward

link and radiates this energy back to the reader. The read range of passive RFID tags is limited by the

amount of energy that the tag can collect from the forward link. This means that if the tag is not able to

collect enough energy to power or back scatter then the system is considered forward link limited.

However, the latest generation of passive UHF RFID tags has lower operating power requirements. As a

result, the read range of these tags is greatly improved when compared with earlier generation tags. In

many situations involving these newer generation tags, the system is not forward link limited but another

potential issue can occur causing the tags not to read. This is that the tag can be powered up but the

backscatter signal is not strong enough to be heard by the reader. This leads to the system being return

link limited.

To further understand how systems can be either forward link limited or return link limited, one must

understand how RF energy dissipates as a function of the distance between the reader‟s antenna and the

tag. This does not occur linearly as one might assume, but rather exponentially. The RF energy level at

a given distance can be explained by a simple formula, Ed=1 ÷ r2 or Ed= r

-2. This is simply that the RF

energy level is dispersing at a rate that is equal to the inverse of the square of the distance from the

antenna. This means that if you measure the radiated signal strength at 2 meters as the reference, at 4

meters (twice the reference distance) the signal strength will be one quarter of the signal strength at the

reference distance of 2 meters.


A-4

RF attenuation directly affects the power level that the reader transmits and receives. A FCC compliant

EPC Gen2 passive UHF RFID system has a maximum operating power of 1000 mw (1 watt) or 30 dB.

When adding a dB of attenuation, a dB is actually subtracted from the overall power level. Another

important fact is that for every 3 dB of attenuation added to the system the power level is cut in half. That

is to say that if 30 dB = 1000 mw then 27 dB = 500 mw (0.5 watts). The inverse of this is also true, for

each 3 dB of gain the power level is doubled – 30 dB = 1000 mw and 33 dB = 2000 mw (2 watts).

Metal surfaces affect the RF field propagation of UHF RFID systems. Every tag in this test was designed

to be able to be read on metal items. All the tags are different form factors and construction methods.

This was done to encompass many of the tag types that are applicable to different use cases and

products. The testing was performed at Alien Technology‟s RFID Solutions Center, which is an EPC

Global Accredited Test Center. The following is an excerpt from the procedure that was utilized to

perform this testing and is an accredited and audited test procedure (this procedure is slightly modified so

that it makes sense in this context).

Procedure

1. Choose qualifying tags from a single lot.

2. Ensure that the test area is clear from ambient RF noise.

3. Connect the transmit antenna to a 50 Ohm, 1 Watt, 2 stage rotary attenuator with 0-80 dB attenuation range (1 dB steps). Connect the other end of the attenuator to the reader.

4. Apply the individual tag to an RF friendly material (Corrugated, Foam etc.) and orient the tag 1-2 M away (BE SURE TO STAY CONSISTENT THROUGHOUT THE TEST ONCE THIS DISTANCE HAS BEEN ESTABLISHED), directly in front of the antenna.

5. Increase attenuation 1 dB at a time until the tag is no longer seen by the reader. Go back 1 dB to verify the tag strength and assign the tag a value in dB that it is last able to be picked up by the reader. This is the sensitivity value.

6. Repeat for all tags at this baseline distance and material.

7. Repeat for all tags at all other desired distances and with all desired materials.

Results. The Omni ID MaxHD tag performed the best, however due availability delay in production

availability; the Omni ID White Brick was initially used. The MaxHD tags became available.


A-5

IPRIME Tag Testing Software. The IPRIME Tag Testing Software was created to identify the optimum passive RFID tag placement on all principal end items and containers aboard MPF ships. The software allowed for multiple locations to be tested simultaneously and reported back the number of reads at each location from passive RFID readers at predefined distances away. This software helped ensure that the passive RFID tags will be read as a vehicle passes by a passive RFID reader during production.

Candidate Passive RFID Tag List for Ship Backload and DACMS Projects

Tag Placement Testing. The SITF provided the infrastructure to characterize and capture the passive tag read range reliability when placed at various locations on military equipment. Six Alien ALR-9812 single-sided portals were set up to form three chokepoints. The distances between each of the portal chokepoints were 10‟, 20‟, and 45‟. The 45‟ distance represented the widest cargo bay door that is used at the Blount Island Command‟s facility. Tags were placed at three candidate locations on the sides of the equipment and the equipment passed through the centerline of the portal chokepoints. The Tag Placement Test software was developed to interface with each of the portals and collect the number of reads at each location. Once the optimal location for the tag‟s placement was determined, a digital photo was taken and incorporated in the iPRIME database. Blount Island Command cycled one of each type of prepositioning equipment through this test fixture in order to select the tags‟ locations and develop a comprehensive Tag Placement Guide.

OmniID MaxHD Passive RFID Tag


A-6

The Tags Are Driven Through Three Chokepoints (6 Portals) and the IPRIME Tag Testing Software Is Used To Identify the Success Rates at Each Location From Portals At the Predefined Distances

Military Equipment Specialists and Passive RFID Analysts Identify and Place Tags At Three Candidate Locations For Testing. The Tags Are Color Coded In Orange, Yellow, and Red.


A-7

The Software Ensures That the Passive RFID Tags and Their Location Placement Will Be Read As the Equipment Passes By a Passive RFID Reader. In This Case the Orange Tag's Location

Was Found Optimal.

Consolidated Memorandum Report (CMR) Inventory

Tag Requirements. The items being tagged for the CMR Inventory are for the most part IT assets,

comprised of a mix of metal and non-metal items. They typically have a small physical area available for

tagging. The tags were required to have approximately a 6 foot read range. Tags were required to have

512 bit extended user memory.

Tags Evaluated. Three candidate tags were selected and evaluated for CMR Inventory. They included

the Omni ID Prox, the Confidex Steelwave Micro, and the RCD Sentry.

Tests performed. Three tests were performed on all tags to determine the optimum range. There was

an on metal read range test, a free space read range test, and an application test in which the tags were

placed on IT assets in mocked up cubicles and read using a mobile cart reader. This last test was for

verification only and concluded the results of the static tests.

Omni ID Prox Confidex Steelwave Micro RCD Sentry


A-8

Metal Non Metal

Horizontal Vertical Horizontal Vertical

OMNI Prox 4.1 ft. 5.5 ft. 2 ft. 2.5 ft.

RCD Sentry 6 ft. 7 ft. 6.7 ft. 9 ft.

Confidex 4.2 ft. 4.2 ft. 3 ft. 2.2 ft.

Results. The RCD Sentry tag had the highest consistent performance across all tests, and thus was

selected for this application.

Container & Mobile Load (CL/ML)

Tag Requirements. The tag requirements for the Container / Mobile Load were based on an evaluation

of the representative items and their packaging. The items were generally packaged in cardboard boxes

or in wooden boxes. Moreover these items required a LOGistics application of automated Marking

And Reading Symbols (LOGMARS) label affixed to the outside of the item or its packaging.

LOGMARS Label

The LOGMARS labels are made of a kimdura material for durability and ultraviolet (UV) protection. This

material acts like paper in terms of the passive tag‟s radio frequency performance. It was decided that

the CL/ML items would use these labels with the ALN-9640 passive RFID inlays. These labels came in

rolls that were fed into the Zebra R110Xi RFID Printer Encoder for printing and commissioning. To


A-9

uniquely identify the metal container, the Omni-ID MaxHD tag was selected based on application testing

in the SITF.

Tests Performed. Testing was conducted with the representative CL/ML items to ensure their readability

prior to the demonstration.


B-1

Appendix B - Acronym Listing

AIT Automated Identification Technology

ATLASS Asset Tracking Logistics and Supply System

BICmd Blount Island Command

BL Backload

BMC Biennial Maintenance Command

C&A Certification and Accreditation

CL/ML Container Load / Mobile Load

CMR Consolidated Memorandum Report

CMS COMSEC Material System

COMSEC Communications Security

DACMS Deployable Automated Cargo Measurement System

DIACAP DOD Information Assurance Certification and Accreditation Process

DOD Department of Defense

DPAS Defense Property Accountability System

DUSD LM&R Deputy Under Secretary of Defense for Logistics and Materiel Readiness

EPC Electronic Product Code

IA Information Assurance

IP Ingress Protection

IPRIME Integrating the Placement and Registration for Identified Material and Equipment

ISO Industry Standards Organization

IT Information Technology

IUID Item Unique Identification

LO/LO Lift-On/Lift-Off

LOGMARS LOGistics application of automated Marking And Reading Symbols

LOI Letter Of Intent

MAGTF Marine Air-Ground Task Force

MCEN Marine Corps Enterprise Network

MCLC Marine Corps Logistics Command

MCPIC Marine Corps Prepositioned Information Center

MCPP-N Marine Corps Prepositioning Programs - Norway

MDSS II MAGTF Deployment Support System II

MIM Mobile Inventory Module

MMC MPS Maintenance Cycle

MPE/S Maritime Prepositioning Equipment / Supplies

MPF Maritime Prepositioning Force

MPS Maritime Prepositioning Ships

MPSRONs Maritime Prepositioning Squadrons

MSC Military Sealift Command

NTPF Near Term Prepositioning Force

PEI Principal End Item

PPS Prepositioned Planning System


B-2

RFID Radio Frequency Identification

SASSY Supported Activities Supply System

SITF Systems Integration & Training Facility

T/E Table of Equipment

TDS Temporary Datastore

TEU Twenty-foot Equivalent Units

UII Unique Item Identification

USD (AT&L) Under Secretary of Defense for (Acquisition, Technology, and Logistics)

USNS United States Naval Ship

UV Ultraviolet


C-1

Appendix C - Container Load / Mobile Load Representative Item Listing

NSN PKG_ID ITEM_I

D DESCRIPTION

1290014125760 0102A E1145 RADAR CHRON SE M94(MUZZLE VELOCITY SYS)

1375002124589 BICB04710012 B0471 DEMOLITION EQUIPMENT SET, EXP INIT N/E

4210007529343 C110346599 K4305 EXTINGUISHER, FIRE, DRY CHEMICAL, 50LB

4910002733658 C110436566 M5000 FILLER AND BLEEDER, HYDRAULIC SYSTEM

4910002897233 4257 C5080 JACK, DOLLY, TYPE-10

4910005165806 B657P24007 C5090 JACK, HYDRAULIC, 4-TON

4910005165806 NB657424053 C5090 JACK, HYDRAULIC, 4-TON

4931013383039 1961 E1907 TEST SET,FIRE CONTROL SYSTEM

5180006063567 BICK49980006 K4998 TOOL KIT, EXPNDBLE SUPPLIES SET, CANVAS, WORKERS

5180012168655 BICD04750018 D0475 KIT, TOOL, OM, 2D ECH, HMMWV



5180013362880 BICE29330001 E2933 TOOL SETM1A1 TANK 2ND ECHELON

5180013821335 695 E2208 TOOL KITELECTRO-OPTICAL

5450007835720 C105833595 J3075 LATRINE BOX, PREFABRICATED

6110015321821 C105826392 B0028 PANEL,POWER DISTRIB

6130015003401 BICK00030002 K0003 CHARGER BATTERY

6625013363372 76810773 H7030 MULTIMETER

7240000893827 C110318037 K4250 CONTAINER, WATER, PLASTIC

7240013375269 C110242148 K4128 CAN,GASOLINE, MILITARY

7530006560811 C110428816 K4730 PLOTTING SHEETS, PLASTIC, 1000 METER SYSTEM SCALE

8145014423343 USMU098759-9 K4237 CONTAINER, DRY CARGO, END OPENING, 8.5X8X20

814501S00E246 GP90800836 KZ017 SMART CART STF

8415002742431 C110357911 K4385 GLOVE, LEATHER, WORK, LINEMAN'S

8415002742432 C110414879 K4385 GLOVES LEA UNLINED M


D-1

Appendix D - Letter of Intent


D-2


D-3


E-1

Appendix E - Blount Island Command Passive RFID Charter


E-2


E-3


E-4


E-5


E-6


E-7


E-8

Passive Radio Frequency Identification Project - … · USMC Blount Island Command Passive RFID...

Documents

Transcript of Passive Radio Frequency Identification Project - … · USMC Blount Island Command Passive RFID...