Chongyue Quartz Factory introduces RFID technology to realize “process visualization”
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Ubiquitous (Ubiquitous) means that anyone, anytime, and anywhere can retrieve the information they need. In contrast, in a U-shaped society, 4W1H (Who, When, Where, What, How) is more important, and RFID plays a pivotal role in assisting the visualization (Visibility) of 4W1H in a U-shaped society. Through RFID technology, it is possible to visualize the inventory status, the shipping process, and the manufacturing process. The results of the visualization allow the previously unknown information to emerge without hiding, and managers or operators can obtain the process from this. Or more complete information about the process, so as to find more accurate ways to improve.
Introduction of Chongyue Quartz and RFID introduction
Chongyue Quartz Manufacturing Plant is a quartz manufacturing company jointly established by the largest quartz supplier in Asia “Shinettsu Quartz” and Taiwan’s professional high-tech semiconductor material supplier “Chongyue Technology”. It mainly produces semiconductor wafers needed for storage. Quartz tubes and related quartz products. There are currently two factories. One is in the Hsinchu Industrial Park, which is responsible for the supply of quartz products from semiconductor manufacturers in the Hsinchu Science Park; the other is in Touqiao Industrial Park, Chiayi, and is responsible for the supply of semiconductor manufacturers in the Southern Science Park.
Chongyue Quartz is based on advanced quartz manufacturing technology, coupled with strict quality requirements, control and adherence to the principles of delivery, so that customers can rest assured to deliver orders, and let Chongyue Quartz become a leader in the domestic quartz processing and manufacturing field.
Since Chongyue Quartz products are produced in many varieties and small quantities, there is no customized process during production. Instead, there are multiple manufacturing processes depending on the product. Therefore, it is difficult to grasp the production status of the product at any time. Therefore, under the spirit of pursuing excellence, management The supervisor hopes to use RFID technology to obtain process information that cannot be grasped under existing conditions, that is, to “visualize” the process. At the same time, Chongyue Quartz’s factory in Chiayi is planning to build and relocate a new factory, so it can be used during construction. The construction of RFID equipment is included in the planning, so that the equipment and the building itself can be optimally integrated, and at the same time, the restrictions caused by the existing building environment can be reduced.
NEC is entrusted to introduce RFID system
Taiwan NEC was approved by Chongyue Quartz after submitting the proposal and accepted the commission for the planning and construction of this project. After 6 months, the system was successfully launched according to the original schedule.
After accepting the customer’s order, Chongyue Quartz will generate a “work order” according to the order content to process the quartz products. The operator takes the work order to first pick the materials according to the work order content, and then follow the products recorded in the work order The specifications are processed on-site, and after completion, the final QC inspection will be entered. If there is no problem, the shipment can be prepared.
The system developed and built by NEC is named “Chongyue Quartz RFID Entry and Exit Management System”. The entry and exit management system is originally in Japanese, which means the record management of work in and out. The essential content is to visualize the process by automatically reading the RFID tags on the work orders that enter and exit the main processes.
The main method is to attach UHF band RFID tags to the work order (Figure 1), and set up RFID reading devices and display screens at the entrances and exits of the main manufacturing process (Figure 2). When the operator carries the work order with the RFID label and the quartz material in and out of each process, the RFID reading equipment at the entrance and exit will automatically read the label on the work order and record the time, so that each process can be entered and exited faithfully. The time spent is recorded.
Job order for RFID label
Figure 2. RFID reading equipment at the entrance and exit of the process
The RFID system can make the information that was hidden and unseen can be presented in detail, and then the more important work is how to convert these huge and complex data into useful information. This is also a very critical issue that is generally neglected when discussing RFID applications. By installing RFID reading devices at the entrances and exits of the main manufacturing process, all the work orders that have passed can be read, and the details are exhaustive. After filtering, analyzing, and discussing with the supervisor of Chongyue Quartz, NEC finally produced a resume that can fully and accurately present the process (Figure 3).
Figure 3. Resume of completed work orders
This result allows Chongyue Quartz’s senior executives to grasp the process history of all quartz products, and even for unfinished products, they can always know the process progress (Figure 4) and estimate the completion time.
Figure 4. Unfinished work order history
Chapter Outside the System-RFID Experience
After half a year of planning, analysis, development, and construction by the NEC team, the Chongyue Quartz RFID entry and exit management system was officially launched in mid-November 2007 in conjunction with the groundbreaking ceremony of the Chongyue Quartz Chiayi new factory. At the same time, during the groundbreaking ceremony, the VIPs with RFID tags attached to the main VIPs were also allowed to have a confirmed RFID experience (Figure 5). After visiting the new factory, the VIPs were allowed to see their factory tour history (Figure 6), in order to cooperate with this.” To realize the “Visibility of Factory Tour”, the NEC team even modified the software in the shortest possible time, changing the original visualization mechanism for work orders to the visualization of VIP visits. Participating VIPs left a deep impression and admired the system while experiencing RFID technology in person.
Figure 5. RFID experience VIP card
Figure 6. RFID experience VIP visit history at the groundbreaking ceremony
Benefits and future prospects of RFID systems
Chongyue Quartz RFID entry and exit management system is provided to the management and management to know the actual time spent in each process for each product, to find the bottleneck in the process and to make effective process improvements. This is the case when there was no RFID system in the past. It is difficult to achieve; in addition, the delivery date of the product can be more accurately grasped. In the past, when a customer asked about the delivery schedule of an order, it was often necessary to go to the processing site because he could not know the progress of the product being processed at any time. Look for the work order for the order and then judge. There are thousands of work orders on site, like finding a needle in a haystack. Nowadays, through the RFID entry and exit management system, as long as the work order of the order is queried in the system, the process history can be seen at a glance, and the completion date can be judged from the history, and customer inquiries can be responded to in real time. In this way, customer satisfaction can be improved. .
Of course, the functions of the RFID entry and exit management system are not limited to this. After the first phase of the system was successfully launched and its results satisfied Chongyue Quartz, Chongyue Quartz also closely reviewed with NEC, hoping to improve this system. Expand its application to other operations, such as inventory and shipment management, to make good use of RFID technology to strengthen the overall application process, and to further stabilize its leading position in the semiconductor quartz manufacturing industry.
Due to the fierce competition in the semiconductor equipment market, if you do not actively carry out various reforms and pursue progress, they will soon be caught up and replaced. This is why Chongyue Quartz introduced RFID technology as the basis for process improvement to expand the successor industry. At the same time, we are not satisfied with this, and further expand this foundation to the key points that can be applied in the overall business process, so that the company’s physique is more stable and standing in a lasting place.
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