Application case of bar code management based on the production line of the Internet of things electrical appliances
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The production efficiency of a company’s electrical production line is relatively low, which is prone to confusion. After consideration, the company decided to adopt the Internet of Things barcode technology to manage production. After the barcode technology is adopted, the order number, part type, and product quantity number are first formed into a barcode, and the barcode is printed and pasted on the production line of product parts and assembly. In this way, the production process and required materials and parts of a product order on a certain production line can be easily obtained. After the product is completed on the production line, the product bar code and production line code number are scanned by the production line quality inspector after passing the inspection, and the worker’s bar code is scanned in the order of the process (it can be confirmed once and unchanged). For unqualified products to be sent for repair, the cause of the failure (process location) is determined by the repair.
The main advantages of barcode application in production management are as follows:
1) The production process of the product can be reflected immediately and effectively on the production line, eliminating the labor of manual tracking.
2) The production process of the product (order) can be displayed on the computer, and the bottleneck in the production can be found; fast statistics and query production data provide a basis for production scheduling, order placement, etc.
3) For the unqualified products in the inspection, it can record the problems caused by the workers or the parts, and provide a practical analysis report.
The following case describes how an electrical appliance company uses bar codes to monitor production conditions during the production process.
The four main goals to be achieved by the system:
1) Quality tracking: It can track the model (mainboard, power supply or other main accessories) of the whole machine and the main substrate (PCB board), production site, production date, team production line, PCB board version number, engineering change (ECO), batch And serial number and other information.
2) Real-time dynamic tracking of production: The actual production situation can be known from the computer at any time.
3) Customer tracking: The customer’s name, address and delivery quantity can be obtained from the computer at any time.
4) Report function: Provide various management reports for management review.
Develop a specific plan
Bar code automatic recognition technology has the characteristics of fast input speed, high accuracy, low cost and easy operation. In the automated assembly production line and various processing processes, bar codes are used to mark the main components with bar code labels. After being collected and decoded by the barcode reader, the barcode information is input into the database of the computer server. Each machine and main component will have a unique barcode. No matter where the machine is sent, there will be records. If there is a problem, you only need to read the barcode on the warranty card, you can call up all the relevant data of the product in the database, which greatly facilitates the quality tracking and after-sales service of the product.
Barcode design
The system can contain four main databases: system design library, user library, PCB library and complete machine library. Barcode label must contain information: model/logo, production site, production date, production team/production line. Batch number and serial number, and barcode tracking system software can accept different barcode format and size requirements. Barcode labels are respectively used on the PCB board, the whole machine, the packing box and the warranty card.
For example, when designing the barcode format of a PCB board, consider the model, production site, production date, production team, production line, batch number, and serial number.
The most important work of this part is each code, which must be able to reflect the various conditions of the product in a timely and complete manner, and be able to achieve the uniqueness of each component.
The main functions of the barcode management system: system management, PCB board production management, assembly production management, warehouse management and other functions.
System Management
System parameter design, system database modification, operator management and password management.
PCB board production management
Print barcode: According to requirements, besides printing the barcode of the PCB board, it will automatically print the barcode of other related accessories at the same time. For the PCB board, the barcode is printed in two copies, one copy is attached to the PCB board; the other copy is randomly used for the final assembly record, so that the barcode of the whole machine and the barcode of the main PCB board used can establish a one-to-one correspondence.
Barcode scanning: Scan the barcode of the PCB board to form a PCB board library.
Statistical analysis: query and make statistics and form reports as required.
Production management:
At each key point of the production line, bar code reading equipment is configured. Workers scan their own work number on the line and record the start time at this station. Scan the PCB bar code, record the work start time, scan the accessory number to be installed at this station, and enter the production data; after completion, enter the completion time and transfer the product to the next station until the product is assembled.
After the product is assembled, print the barcode of the whole machine and the packaging box according to the number of the PCB board, and send the packaged product to the warehouse.
Print barcode: Print the barcode on the whole machine, packing box and warranty card.
Barcode scanning: Scan the whole machine to form a finished product library.
Statistical analysis: query and make statistics and form reports as required.
Warehouse management:
At the beginning of warehousing, fixed scanning equipment is used to scan the finished product packaging barcode of the warehousing assembly line, and the warehousing time is recorded to form the warehousing registration of the finished product, and the inventory in the warehouse increases. When leaving the warehouse, scan the barcode of the package box of the whole machine according to the outgoing plan to verify whether the outgoing product data is consistent with the plan. Complete the outbound operation.
Using the whole machine bar code and handheld bar code scanning terminal, you can also carry out inventory work in the warehouse.
Using bar codes to encode storage locations and shelves can realize the kinetic energy of automatic warehouses, and use bar codes to locate and automatically enter and exit the warehouse.
Warehouse entry and exit management: Generate entry and exit lists, and form entry and exit reports by scanning products in and out of the library.
Statistical analysis: query and make statistics and form reports as required.
other functions:
Quality tracking: According to the barcode of the whole machine, query the model (mainboard, other main accessories) and production data of the main PCB board used.
Query system: query various production conditions and quality information of the system, including daily output, weekly output, monthly output, stage output and inventory, PCB board number and other data.
Report printing: Print various reports.
Other formats: The management software can accept different formats, that is, the way of bar code composition can be set by the user.
Warehouse center: warehouse management inside the factory and remote management outside the factory.
After-sales service: Warranty card and maintenance and repair record management.
The manual operation in the past has become less and less adaptable to the requirements of modern management under the new situation. Computer technology and bar code technology have become an inevitable trend in the field of production quality management, such as the original production schedule and daily, weekly and monthly output reports. All of them are made after manual statistics by multiple people, which is labor-intensive and cumbersome to repeat the work. After adopting the barcode tracking system, the above-mentioned reports are all automatically completed by the computer, and the work is simple, convenient, accurate and fast. Through data collection, management, retrieval, archiving, and real-time statistics, quality information and dynamic reflection of production status enable production managers to understand the production situation in a timely, accurate and comprehensive manner, so as to take necessary and effective measures to ensure that the production can be The scheduled plan is proceeding normally. After the production line adopts the barcode management system, the quality and management level can be greatly improved, and it will bring significant effects to the decision-making and management of the enterprise.
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