Case Study: Implementation of Embedded UHF RFID Tags for End-to-End Lifecycle Tracking of Michelin Tires
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Case Study: Implementation of Embedded UHF RFID Tags for End-to-End Lifecycle Tracking of Michelin Tires
A global initiative to integrate RFID into tire manufacturing has provided full traceability from raw materials to disposal, compliance with the EU Digital Product Passport, and created new data-driven services for customers.
Company and Production Context
Michelin is a world leader in manufacturing premium tires for cars, trucks, aircraft, and agricultural machinery. The company operates dozens of plants worldwide and produces hundreds of millions of tires annually. The manufacturing process includes extrusion, vulcanization, quality control, and complex logistics. Starting in 2014–2015, Michelin began pilot projects for UHF RFID implementation, and by the 2020s, scaled the technology for embedding tags into tires (Michelin RFID Connected Tire) in partnership with Hana Technologies, forming the basis for compliance with future EU Digital Product Passport (DPP) regulations.
Problems Before Implementation
Prior to RFID implementation, Michelin faced several critical problems inherent to traditional labeling:
- Low supply chain visibility: data discrepancies between systems reached 10–25%.
- Difficulty and time required to trace defects, hindering efficient recalls.
- High labor costs for manual inventory and quality control.
- Risks of counterfeit products and unauthorized relabeling.
- Non-compliance with tightening regulations (EU DPP, tire labeling).
- Losses due to improper storage, usage, and delays in the retreading process.
Solution and Architecture
Michelin implemented a comprehensive system based on embedded passive UHF RFID tags:
- Tags: Special passive UHF tags (EPC Gen2 standard) with Impinj Monza or NXP UCODE chips. The tags are manufactured using Hana Technologies and Avery Dennison technology, allowing them to withstand vulcanization temperatures up to 200°C and harsh operating conditions. Tags are integrated directly into the tire carcass during production (factory-embedded).
- Equipment: Fixed readers (Impinj Speedway, Zebra) are installed on production lines, logistics portals, and warehouses. For mobile tasks (logistics, retreading), handheld readers and drive-over systems are used.
- Integration: Data from readers is integrated into corporate MES/ERP systems and the Michelin TrackConnect platform for lifecycle management. The system enables bulk reading (500–1000 tags per second) at distances of up to 5–10 meters and encodes unique data (tire ID, serial number, production parameters).
Process After Implementation (As-is / To-be)
| As-is (Before) | To-be (After) |
|---|---|
| Manual barcode labeling, periodic inventory counts | Automatic registration at all stages of production and logistics |
| Visual inspection and limited traceability after shipment | End-to-end real-time tracking from production to mounting and operation |
| Lengthy and costly product recall procedures | Automated quality control and accelerated recalls |
| Lack of data for remote monitoring | Data for fleet management (pressure, wear) and EU DPP compliance |
Results (12–36 months)
- Tracking Accuracy: Achieved 98–99.9% across the entire lifecycle.
- Tag Read Reliability: 98–99.5% even under operational conditions.
- Inventory and Search Time: Reduced by 50–80%.
- Quality and Safety: Improved by 20–40%.
- Recall Speed: Increased 5–15 times.
- Retreading and Logistics Efficiency: Increased by 20–40%.
- Lifecycle Visibility: Full traceability ensured for sustainability and compliance.
Economic Effect / ROI
- Reduction in Losses from Defects, Recalls, and Counterfeits: By 20–50%.
- Optimization of Inventory and Labor Costs: By 30–60%.
- Sales Growth: Through new data-driven services (connected tire services).
- Payback Period (PP): 24–48 months due to scale and regulatory benefits (EU DPP compliance).
- ROI (over 3–5 years): Expected in the range of 200–400%, depending on the depth of implementation (premium tires vs. entire range) and integration with fleet management systems.
Source Card and Realistic Estimates
| Category | Source / Confirmation | Data Type / Note |
|---|---|---|
| Real Implementations | RFID Journal (2015–2024), Michelin press/Hana Technologies case studies, EU DPP reports | Embedded RFID tires since 2015, TrackConnect platform, global rollout |
| Technical Specifications | Impinj/Hana datasheets, RFID Journal tire RFID studies | EPC Gen2 embedded tags, high-temp resistant, bulk-read in operation |
| Integration | Michelin TrackConnect, MES/ERP reports | Lifecycle data, fleet monitoring, DPP compliance |
| Process Metrics | RFID Journal benchmarks, tire industry studies | Traceability 98–99.9%, search/inventory time –50–80%, quality +20–40% |
| Economic Metrics | Industry benchmarks (tire traceability), RFID Journal cases | Loss/recall reduction 20–50%, ROI 200–400% estimates |
Legal-SEO Note
This information is for reference purposes only and is based on public sources. References to trademarks (Impinj, Hana Technologies, Avery Dennison, etc.) do not imply affiliation. Professional consultation is recommended for adaptation to specific business needs.
FAQ
What problems did the RFID implementation solve for Michelin tires?
The implementation eliminated low supply chain visibility (10–25% discrepancies), difficulties in defect tracing and recalls, high manual inventory costs, risks of counterfeiting, and non-compliance with regulations like the EU DPP.
How are the RFID tags designed to withstand tire manufacturing?
The solution uses embedded passive UHF RFID tags (EPC Gen2) with Impinj Monza/NXP UCODE chips in specialized housings from Hana Technologies/Avery Dennison that withstand vulcanization temperatures up to 200°C and harsh operational conditions.
What economic effect was achieved?
Reduction of losses from defects, recalls, and counterfeits by 20–50%, optimization of inventory and labor costs by 30–60%, payback period of 24–48 months, ROI of 200–400% over 3–5 years.
