White Paper

MACHINE OPERATOR AUTHENTICATION

ENABLING WORKFORCE TRACKING AND OPTIMIZATION
THROUGH SECURE AUTHENTICATION

Operator identity is often a missing link in manufacturing data. To optimize plant processes,
manufacturers need to know not only what machines and materials were used and at what times
but also who was in control. Reliable and secure operator authentication is critical for plant security
and IP protection, effective workforce tracking and management, and manufacturing optimization.
THE IMPORTANCE OF KNOWING “WHO” WHY DO YOU NEED TO
Industry 4.0 is all about data. The “Industrial Internet of KNOW WHO?
Things” (IIoT) enables manufacturers to track various
metrics highly granularly across the entire production Machine operator identity
cycle, from material usage to production yields to total provides greater visibility into
cycle time. Centralized data analysis within a Manufacturing worker activity, productivity,
Execution System (MES) allows unprecedented insights per-unit labor costs and other
into production capacity, equipment uptime and utilization, important metrics, enabling
maintenance requirements, and other critical aspects of data-driven decisions around:
plant performance. Using data to drive decisions helps plant + Training Needs
managers and executives identify areas for improvement,
+ Quality Control
optimize processes, and improve productivity and cost
control. + Machine Troubleshooting
+ Scheduling
One crucial metric is often missing in all this data: operator
+ Compliance
identity. We may know exactly how much time a piece
+ Workforce Optimization
of equipment was powered on, what tools and materials
were used, and precisely what was done the entire time the
machine was operational, but not who was in control.

In most factories, workers gain access to the building and clock in using a company ID badge but
use other, less trackable means of authentication to access individual production cells, machines
or vehicles on the production floor. Shared physical keys, RFID fobs or PINs are still common for
access to production equipment and material-handling vehicles. Some machines have a Human-
Machine Interface (HMI) that requires a username and password, but these may be commonly
shared in some company cultures. This means that managers have limited visibility into the
activities of specific workers beyond the clock-in and clock-out times and no way to track which
workers were operating which machines at what times.
Without operator identify, manufacturers are missing an essential element of plant optimization.
Reliable operator authentication at the machine level is needed to link metrics such as material use,
product quality and production output to individual workers. By tracking workforce activity at the
machine level, manufacturers can gather valuable insights into individual and team performance,
allowing them to optimize processes, improve productivity, minimize variation and enhance overall
plant performance.

HOW WORKFORCE TRACKING ENABLES MANUFACTURING

OPTIMIZATION
Workforce tracking refers to the ability to accurately identify individual workers and monitor their
activities as they interact with various machines and equipment within the manufacturing facility.
This is achieved through reliable and secure authentication methods that link their unique operator
identity to a specific piece of equipment at a particular time. Linking operator identity at the individual
machine level—and not just at the cell or line level—
provides much more granular detail into how workers
spend their time across each shift and how individual CASE STUDY:
machines are utilized, by whom, and for which
TRACKING PRODUCTION COSTS
projects. Adding operator identity to all the other
AND OPERATOR EFFICIENCY
data collected in a manufacturing facility provides A multinational engineering and
critical insights that allow managers to make better technology company customer of Polaris
workforce and production management decisions. Automation, Inc. wanted to get better
insights into the true production costs of
individual part numbers. This required
greater granularity into how much time
individual workers spent in various
operations across the plant.
Workers used their company ID badge to
clock in at the beginning of the shift, but
the company had limited visibility into how
individual workers spent their time once
clocked in. Polaris Automation specified,
and the customer added, universal RFID
readers from ELATEC to the HMIs of each
individual machine across the plant. This
allowed workers to easily sign into each
In addition to user identification, a machine machine.
authentication system also allows access levels to be Machine authentication enabled the client
set for individual users. This prevents unauthorized company to get a better picture of unit
or untrained personnel from operating expensive costs by looking at how many people were
machinery, protecting assets, production processes, at each station and for how long. Now, they
and valuable IP that may be held on the machine, can track not only machine performance,
such as part or tool specs. Machine authentication but also operator performance on each
and workforce tracking support compliance with piece of equipment, so they can identify
increasingly strict industry and government standards training needs and improve efficiencies
across all operations.
and insurance requirements for occupational safety
and cybersecurity. Access levels can also be set
for different types of users based on training levels,
certifications or job responsibilities. For example, different WHY RFID?
access levels may be set for line operators, supervisors
+ Enables reliable
and maintenance technicians that dictate which machine
identification and
functions they are authorized to access, change or control. authentication of individual
Secure access control improves plant safety and minimizes operators
the risk of intentional or accidental damage to equipment + Secure, encrypted
and production line disruptions. When we know exactly communication between
who is operating each machine at all times, we can use the card and reader
that data to drive workforce and production optimization in prevents cloning or hacking
various ways. + Fast and contactless, so it
won’t slow workers down
+ Labor costs: What are the actual labor costs for each
+ Works even in dirty, hazy or
piece going through the production line? How much humid factory conditions
time are different employees spending on each piece,
+ Can leverage the same ID
and during what processes? card workers already carry
+ Workforce utilization: Is the workforce fully utilized at for building access
all points in the shift, or are there times when some
workers are waiting for a machine to be freed up or for
a more experienced technician to become available?
Do adjustments need to be made in scheduling or in the physical layout of the production line
to ensure that machine availability matches worker availability?
+ Operator efficiency: How does each operator’s performance compare to others? Are there
variations in output, quality, or speed that can be attributed to individual workers? Can these
differences be used to identify best practices or areas where additional training is needed?
+ Machine preferences: Do certain operators perform better on specific machines or tasks?
Can this information be used to assign workers to the most appropriate machines or tasks,
optimizing both individual performance and overall productivity?
+ Safety and compliance: Are there any patterns of non-compliance or unsafe behavior among
operators? Can targeted safety training and enforcement be implemented to reduce risks and
ensure compliance with regulations and best practices?
+ Skill gaps: Are specific skills or competencies lacking within the workforce? Can targeted
hiring, training, or mentorship programs be implemented to address these gaps and improve
overall workforce capabilities?

MACHINE AUTHENTICATION WITH RFID

To make workforce tracking effective, manufacturers need a reliable way to track employee
activities down to the individual tool and machine level. A machine authentication system that
crosses all tools, machines, robots, vehicles and equipment provides complete transparency into
worker activities across the shift; managers know exactly where each person was at any time and
what they were working on.
Radio-frequency identification (RFID) provides secure, reliable
user authentication and access control for industrial
machines. For most manufacturers, an RFID reader
that can read the same badges that employees
already use for building entry is the optimal
choice.
+ RFID is easier to manage and more
secure than a password or PIN
system, reducing IT time and
minimizing hacking risks.
+ Unlike shared physical keys or
fobs, it enables identification of the
individual operator.
+ In contrast to biometric systems,
RFID does not require workers
to remove masks or gloves for
identification.
+ RFID is reliable even in hot, hazy, dirty,
or high-humidity environments, where
technologies like biometrics, magstripe cards
or optical readers can fail.
+ In environments where mobile device use is practical
and safe, RFID readers can also be configured to allow
authentication via NFC or Bluetooth® Low Energy (BLE).
RFID readers enable workers to sign into individual machines quickly and easily as they go about their
day. Authentication is fast and contactless; workers simply wave their ID card (or, in some cases, a
smartphone or wristband) near the reader, which is connected to the HMI and/or programmable logic
controller (PLC) for the machine. A unique operator identity number is used to identify each user. The
reader can send information to the MES or other backend systems to enable efficient workforce tracking
and confirm that the operator is authorized to use the equipment.

HOW RFID WORKS FOR MACHINE AUTHENTICATION

RFID cards have two main components:
+ an integrated circuit that can store and process information
+ an antenna to transmit or receive a signal
Each RFID card stores a unique data set—such as a number—that serves to identify the card and, by
extension, the person carrying it. When a card with an embedded RFID tag is in close proximity to an
RFID reader, the reader transmits a radio signal to interrogate the tag. The radio signal activates the tag,
which then uses the power in the radio signal to respond to the reader with its unique ID.
The reader can be embedded into the machine, tool or robot. Once the tag is read, the reader connects
to backend systems to confirm access levels for the operator. If authorization is confirmed, a signal is
sent to the HMI or PLC to enable operation. Differentiated access levels for machines can be set based
on operator identity.
ACCESS SOLUTIONS FOR THE SMART FACTORY
Machine authentication is just one access application for the smart factory. In a unified access system,
employees can use their company ID badge to access everything they need across the plant, from
physical access to production areas and elevators, to sign-on to workstations and printers, and even
company amenities such as parking, EV charging, vending and the cafeteria. A harmonized access system
provides even more granular detail into worker movements and activities across the shift. It also offers
convenient access for employees while enhancing security and safety for the plant.

To make it all work, manufacturers need a reader

compatible with the access technologies they UNIVERSAL ACCESS: THE ELATEC TWN4
already use for building entry and time-and- MULTITECH LINE OF READERS
attendance. That way, workers don’t have to Powerful, versatile readers for Smart
carry multiple cards to access different machines Manufacturing.
and applications throughout the factory. Workers
+ 60+ transponder technologies, plus mobile
are also much less likely to share their primary authentication via NFC and BLE
ID cards. A unified system is more convenient
+ Wide range of form factors and housing
for workers and simpler for IT to set up and options for a variety of applications
manage.
+ Powerful software development kit for easy
ELATEC’s universal RFID readers provide an customization
optimal solution. With a universal reader, + Encryption for secure and sensitive industrial
manufacturers can leverage the identification applications
media they already have in place for easier + Secure remote updates for easy
implementation of machine authentication and reconfiguration and security maintenance
other access applications. And with various form + Certified for use in as many as 110+ countries
factors and a powerful software development kit,
the readers can be integrated into a wide variety
of machine and device types.
While a critical component, the RFID reader is but a part of the total solution. ELATEC leads by bringing in
appropriate partners to develop and implement the optimal solution based on the end customer’s needs,
including such requirements as communication with the factory network via MQTT.

THE ELATEC ADVANTAGE FOR THE SMART FACTORY

ELATEC’s powerful, flexible reader technology gives manufacturers and system integrators a real
competitive advantage, both now and in the future. ELATEC can help OEMs, system integrators and
machine builders developing Smart Factory solutions:

+ Expand internationally: ELATEC readers are certified for sale in as many as 110 countries globally.
+ Maximize market opportunities: ELATEC readers support nearly every card technology available,
including HF and LF, and an ever-expanding portfolio of compatible mobile credential access
control solutions via BLE and NFC.
+ Reduce total lifecycle costs: ELATEC readers simplify inventory management with a virtual single-
part number solution and can be easily and remotely updated or reconfigured without replacing
inventory.
+ Deliver customer advantage: ELATEC readers reduce configuration expenses, extend product life,
and support advanced functionality and security requirements, providing product differentiation
for device manufacturers and software developers.
+ Prepare for the future: With ELATEC, you’ll be ready for whatever comes next. Our readers can
be reconfigured to address emerging opportunities and customer requirements.

Service Products Software

The world’s best RFID products Find the optimal product for Our software solutions help you
and software come with the every project. We offer single- get the most out of your RFID
world’s best service. Our team and multi-frequency readers/ reader/writer. Our Software
is with you all the way with writers in many configurations. Development Kit lets you

© 2023 ELATEC, Inc. –5/2023. All names are registered trademarks of their respective owners.
expert advice and hands-on We can also customize configure your reader with
help, from needs analysis solutions for your application – easy-to-use software tools for
and product selection to no other reader on the market your exact security standards,
implementation and post-sales offers more options or can be communication protocols, and
support. customized as quickly! IT infrastructure.

READY TO GET STARTED WITH MACHINE AUTHENTICATION?

The access control experts at ELATEC can help you design an authentication system that fits
your production environment.

Contact us for a consultation.

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