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1. Project background
In traditional manufacturing companies, daily management is more concentrated in product management, quality management, warehouse management, mobile asset management, on-site personnel management, fleet management, and so on. The collection of production line information usually adopts manual collection and manual input. This method of manual collection and manual input is far from accurate and has a large error rate. In addition, manual input can only be done regularly, which results in the production plan being submitted on a weekly or monthly basis, which cannot be accurate to the day. The production data in the system cannot be updated in real time, and the lag is serious, which is not conducive to the smooth progress of the production flow and restricts the further increase of production capacity. At the same time, most functional departments of manufacturing enterprises mostly use paper and pen primary recording methods, which makes most functional departments of manufacturing enterprises face a large number of data errors and reduces the overall productivity of the enterprise.
Manufacturing companies have realized the existence of these problems and tried to use emerging technologies to solve these problems. At present, some manufacturing enterprises use barcode recognition to improve the accuracy of data entry, but there are still technical bottlenecks in barcode recognition:
1. The different efficiency of workers can easily cause uneven division of labor in the group;
2. Production abnormalities and production line bottlenecks cannot be found in real time;
3. The labor efficiency is low, and the actual working time utilization rate is not high;
4. Once the barcode label is not clearly printed, there are problems such as folding marks, the barcode gun is difficult to identify;
5. Real-time tracking is not possible, and it is difficult for the management to arrange work according to the work status. If there is a problem in a certain process of the work process, it must be eliminated until the next day;
6. Barcode data collection requires a dedicated team of personnel to operate, and labor costs are high;
Therefore, the production line management system represented by barcode recognition has become increasingly unable to meet the requirements of enterprises for efficient and lean production management. While deepening modern management concepts, it is of great significance for enterprises to build a more advanced technology production line management system.
2. Project definition
RFID radio frequency identification technology is an emerging high-tech technology that has caused changes in the field of automatic identification after barcodes. It uses the penetrability of wireless electromagnetic waves, the characteristics of long-distance transmission and high-speed data exchange, and achieves identification through specific protocols. Technology for automatic identification of item information. In the manufacturing industry, compared with the currently widely used barcode technology, UHF UHF RFID technology has essential advantages: wireless long-distance reading and writing, penetrating reading and writing, and high-speed movement Read and write, store more data, can be used in harsh environments, etc. Therefore, RFID technology is not just a simple replacement of bar code technology, its application in the manufacturing industry will change the production and operation of enterprises.
The construction of a production line management system based on UHF UHF RFID technology is based on a computer network, with RFID as the core, building conforms to the production management requirements of the enterprise, and aims to solve the existing problems of the enterprise, from the production line semi-finished products offline, warehouse transfer and storage A comprehensive management system for automatic real-time data collection in the entire process of temporary storage and on-line production, and tracking and management of cargo batch box numbers.
As a data carrier, electronic tags can play the role of identification, item tracking, and information collection. The RFID system composed of electronic tags, readers, antennas and application software is directly connected to the corresponding management information system. Every item can be accurately tracked. This comprehensive information management system can bring many benefits to customers, including real-time data collection and tracking management. Therefore, RFID technology is applied to the tracking and management of goods conversion between production lines. It can effectively prevent errors, realize intelligent production line logistics management, and greatly improve the production line management level of the enterprise.
Three, system design
The production line management system based on RFID technology applies advanced RFID radio frequency identification technology in the production line, transfer and temporary storage warehouses, and uses reusable radio frequency electronic tags. Each tag has a unique ID number and a readable and writable data area. , Write product information into RFID electronic tags, install readers at the offline stations of the production line and warehouse entrances, automatically write and collect product information at each location by reading and writing tag information, and share data information with other IT systems, The information is displayed on the screen at the same time, prompting the production line operator, so that the semi-finished products are transferred from the offline to the warehouse, temporarily stored, and then online for the whole process tracking management, so as to ensure the correspondence of the batch box numbers between the production lines , Each production line can complete production tasks without error, and record important information in the production process, which can provide basic data services for future quality information traceability.
3.1 Construction goals
Manufacturing production line companies introduce RFID, combine RFID with existing IT systems, establish a real-time production line management system, optimize and rationally use resources, increase production capacity, increase asset utilization, and higher levels of quality control and various online measurements Create greater benefits for the enterprise.
RFID provides a constantly updated real-time data stream. Complementing the manufacturing execution system, the information provided by RFID can be used to ensure the correct use of labor, machines, tools, and components, thereby achieving paperless production and reducing downtime. Furthermore, when materials, parts and assemblies pass through the production line, the production process can be controlled, modified and even reorganized in real time to ensure reliability and high quality. All data is collected by the client computer at high speed via wireless means.
With real-time data flow as the basis, management systems such as ERP can mine these large amounts of data, conduct real-time and effective supervision of production schedules and processes, identify production bottlenecks, solve production problems, and deploy higher-level quality control and Various online measurements.
RFID can provide the most accurate calculation results of the man-hours required for the process. ERP software can accurately evaluate each worker’s process and working hours through RFID, and calculate the actual production capacity of each production line. Enterprise managers can use these data to make more accurate analysis of the company’s business capabilities.
Complete data mining and analysis. Enterprise managers can master workshop production capacity, solve production bottlenecks in real time, monitor production progress in real time, and improve production processes through quality monitoring. RFID provides the basis for enterprises to achieve a balanced production line, and is compatible with enterprise ERP, SCM, MCS, etc. The combination of mainstream management systems allows every employee in the enterprise to maximize energy efficiency.
3.2 System network diagram
The network diagram of this system is as follows:
The system mainly realizes the intelligent management of the entire production line from card issuance to station management and warehouse management.
3.3 System process
3.3.1 Card Issuing Management
Arrange the production plan according to the production order, including production order import, order statistics and status information transfer, production task decomposition, automatic task assignment, etc., make and issue electronic labels according to the production plan, and bind the electronic labels to the goods that need to be managed. And through the ERP sharing interface to obtain product-related information, write the information into the electronic label, such as batch, box number, etc., establish product files in the production management system, and fully track the conversion process of the goods production line.
3.3.2 Workplace Management
RFID readers and antennas are installed at each station. When the goods with RFID tags enter the RFID working point, the reading (writing) device reads the data information stored in the electronic tag on the product; the reading (writing) device reads The fetched electronic data information is directly transmitted to the logistics control management information system. The management system then lists the package number and batch information of the goods according to the product production information, and displays it on the display screen to prompt the production workers to perform the correct operation.
3.3.3 Warehouse Management
After the goods are processed on the production line, they need to be sent from the production line to the transfer warehouse, and RFID channel-type reading equipment is installed in the transfer warehouse to realize the automatic collection of cargo information and real-time background data update in the warehouse. The goods are delivered from the warehouse automatically and in batches in the same way, realizing real-time and efficient management of the goods.
4. System revenue
The establishment of a production line management system based on RFID technology can bring the following benefits to enterprises:
1. Production data can be collected accurately and in real time;
Real-time feedback of production data is the basis for ensuring smooth production operations. The real-time production data collected by the system in the production workshop is automatically collected by RFID equipment in real time. The impinj RFID reader reads the specific information contained in the RFID electronic tags of the goods and feeds it back to the system in real time. The server updates the data every 5 seconds. . Through this operation mode, the system can provide real-time production data for collection and data analysis.
2. Productivity is improved on the original basis
Productivity is the focus of production management and it is also the difficulty of management. If the productivity is increased, it means that the output of the enterprise will increase and the profit can increase. The real-time production data of the production workshop is fed back to the system. Through system monitoring, the reasons that hinder the smooth flow of the production line can be found in real time, and the production bottleneck can be found in time. The system monitors the production situation of each workshop, each group, and each station in real time through real-time data collection, so that abnormal conditions in any production link can be found, and the bottleneck that hinders production flow can be solved in time. As a whole, the smooth flow of the assembly line is guaranteed and productivity is improved.
3. Real-time tracking of order progress to ensure timely delivery
If the order cannot be delivered in time, it means that the company will not only be unable to make a profit but will lead to a loss, and it will also affect the company’s reputation. The future development of the company has been greatly affected and hindered. Especially export companies are more important for the timely delivery of orders. The system starts from the customer’s order, and tracks the real-time progress of the entire production process of the products to be produced from the start to the end. Track the progress of orders on the production line in real time, so as to accurately grasp the production progress of each order and achieve the purpose of timely delivery.
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