Nanwei Yueda Garment Workshop Data Management-Garment RFID Field Management
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Ruixiang analyzes common confusion problems in the workshop:
-General workers in the workshop often have the habit of storing work tickets. This omission not only increases overtime costs, but also affects the factory’s inability to accurately grasp the output of workers.
-Low production efficiency is mainly due to the lack of strict quantification in management, lack of planning in production, low equipment utilization, and non-coordination of personnel arrangements.
-Supervision is out of control. When there is a delay in production, an early warning notification is not issued in a short time. The uneven performance of the employees in the production line lacks data measurement, which seriously affects the production progress.
-Lack of data for operational analysis. At present, many factories have used various types of computerized technology networks to control production operations, and these computer program modules support a variety of proprietary settings. In addition to increasing maintenance costs, this situation has also become difficult to collect data for enterprise planning (real-time statistical data in the production process).
Therefore, a comprehensive enterprise information management planning system, such as the RFID technology of Ruixiang specializing in WIP production process-RFID production management solution, and the ERP solution of Ruixiang clothing industry, are the silver bullets of the enterprise.
Introduction to Ruixiang’s use of RFID technology in workshop management
The operation of Feizi in the traditional production line is compared with Ruixiang’s use of RFID record cards in the WIP process flow: replacing the paper-printed work ticket (Feizi) of the production line.
It is difficult for general management to use the “work ticket flying boy” as a tool to understand and track the production progress. Workers will not only save the flying boy before handing it over before the grain period (or transfer it to false wage reports when working overtime), and increase the calculation of the grain. In addition to processing and cost, the actual progress of production will also be confused. The RFID system provided by Ruixiang adopts the pre-set production data of each component to be stored in the RFID system, and the RFID record card is used for the production process management in the WIP process flow. When the RFID production card passes through the reader in front of each trolley or production machine, the start and end of each process can be transmitted to the main server database in real time. The program will automatically calculate and count the production progress and piece rate to achieve “real-time production” The comprehensive tracking control of “management process” provides a large amount of analyzable data for production department balance, worker output value, equipment utilization rate, etc.
Through the computer, Ruixiang transmits the real-time production process to the management personnel of all levels, which greatly improves the transparency.
How to implement the recording, transmission and management of real-time information in factory production will be discussed in detail at the implementation plan level.
Ruixiang-RFID Production Management Solution
Ruixiang-RFID production management solutions, application production categories include woven, knitted, underwear, wool, swimwear, jackets, handbags, shoes, etc. One of the most praised by customers is that the use of the system will not change the original operating mode. Nowadays, most of the production modes of garment factories in China and Hong Kong are based on Bundle Production Mode or Unit Production Mode. The biggest disadvantage of this streamlined production line model is that there is often a backlog of semi-finished products/work-in-process (WIP), such as complicated processes and lengthy production processes, which weakens the manufacturer’s ability to predict, control and respond to the production cycle. The traditional production management model has become more and more difficult to meet the market requirements of fast response and extremely short delivery time. The RFID production management program provided by Ruixiang for the apparel industry is definitely an IT solution for this problem. Simply put, the RFID production management solution is to add RFID technology to the integration process of different pieces of clothing, and systematically track the progress of processing and production in each production line. Different from general production line management methods, RFID production management solutions are not hindered by the complexity of different production areas and styles that hinder the tracking of “real-time” production data.
Real-time is one of the advantages of this system-the RFID production management solution provides “real-time data” of the production line. Good management emphasizes balanced production and encourages overall operations, not purely pursuing individual output. The transfer of semi-finished products between processes and processes is very close, because any obstruction will directly affect the operation of other processes in production, so the overall production of workers and mechanical capacity arrangements are based on the principle of smooth production processes. In addition, the management itself must strictly limit the inventory of semi-products. Based on the short-distance design of the production system and the principle of simultaneous production, the storage of semi-products will not be large at all. These restrictions and rules need to be digitized, standardized, and Computerized.
Jiangsu took the lead in successfully adopting RFID production management solutions. One of the factories was a joint venture garment factory (Yueda Textile Group) in Yancheng, Jiangsu. When asked about the secrets of using RFID production management solutions, the person in charge of the factory said that balance Running water is very important. To achieve a balanced flow of operations, you must first have a proper production plan and manpower arrangements. In conjunction with the Ruixiang system, the factory’s production line engineering team will conduct process analysis and time research on the order styles before production, and formulate a production plan, including process time, daily estimated production volume, and mechanical equipment layout drawing into the system. These production data are also the production indicators of the cutting machine department, and the backlog of cut pieces is reduced by the production method. The management emphasizes that the RFID production management plan can make the production process digital and computerized, so that the past problems can be “understood.” “. Only on the system monitoring screen, managers can use visual management calmly, discover and solve production problems in a short time, greatly reducing the possibility of problem backlogs. If necessary, deployment revisions can be made at any time during production to reduce the problem of unbalanced production lines, and overall productivity can be improved while costs can be relatively reduced. In general, the RFID production management solution solves the problems of the traditional production mode of semi-finished products, difficult quality control, and long production cycles. In today’s clothing market with meager profits, diversified customer requirements, and fierce competition, these common problems are often fatal. For the clothing industry, we should learn from them.
Ruixiang’s RFID production management solution: tracking people/things/events, and synchronously for real-time data collection
From the perspective of the integrated supply chain (Integrated Supply Chain), the RFID system greatly improves the transparency of each link of the supply chain (different supply chain projects in different regions), and items (including processes) can be tracked in real time anywhere in the supply chain. In terms of the depth and breadth of supply chain integration, integration can be divided into four levels: more accurate information integration, more effective synchronization plans, more effective collaborative workflows, and comprehensive supply chain integration. RFID makes revolutionary changes at every level, truly realizing real-time supply chain integration.
Ruixiang senior consultant pointed out that RFID technology optimizes and integrates the supply chain environment, and provides a brand new business operation mode for supply chain participants, enabling enterprises to pursue their goals more effectively.
Real-time information. RFID does not require human hands to identify the tag, the reader directly reads the relevant data (employee card, process card) in the smart card from the radio frequency tag. Some card readers can read the data of one or two hundred labels in a very short time, which is a thousand times faster than the traditional scanning method, saving a lot of labor resources (only relying on manual processing). Take production line management as an example. In a supply chain environment with a well-integrated RFID WIP and ERP system, due to the high degree of information sharing, process progress information is placed in the information flow of the entire system and can be queried in real time by all participants and managers , The stored data can be used for wage calculation purposes, further reducing manpower and errors.
Secondly, the RFID system can effectively promote the supporting enhancement of the supply chain (including the ERP system). In a highly coordinated and integrated environment, information flow can cooperate with logistics and capital flow to achieve more flexible business processing, but it is even more critical to effectively link information flow with related businesses. RFID technology is implemented through an ERP system across departments (and even across different cooperative partners). Upstream suppliers and manufacturers and downstream distributors and retailers can track and obtain first-hand information during production progress, thereby reducing inventory In order to reduce the occupation of mobile data, materials and products can be stored more accurately and efficiently.
Furthermore, real-time supply chain management is truly achieved. Comprehensive global supply chain integration is like a large-scale virtual enterprise organization. Each member of the organization shares information, synchronizes plans, and uses coordinated business processing procedures to cope with the complex and changing market and provide end customers with efficient, fast, and efficient Flexible business, gain advantages from it. Through the information system platform integrated with Ruixiang’s RFID production management program, the production line and procedures can be clearly and accurately displayed in any situation. Each supply chain participant can gain insight into the status of the entire supply chain, and make the entire supply chain better. The response speed and accuracy are greatly improved.
R&D and innovation, tracking the various links of the clothing supply chain
In order to focus on and cope with the complexity and particularity of the apparel industry supply chain, RFID system tracking is not only in the cutting bed, film room, workshop, ironing department, packaging, etc., but the development and research department of Ruixiang has more washing processes. , Self-developed high-temperature resistant RFID tags, unique openings and thick body design can prevent the tags from falling off and not damaging clothing materials when the washing machine is in operation, so it is the selling point of the new type of tags.
Application examples, the efficiency index is immediate
As a large-scale garment manufacturer in the Yangtze River Delta, Yueda Textile Group has more than 1,000 workers and an annual output of hundreds of millions of pieces, which are exported to major clothing retailers in Europe, America and Australia, such as Wal-Mart.
In a garment factory, the management of workers and the supervision of production schedules are not an easy task. As far as wage management is concerned, in order to encourage workers to work more and earn more, clothing companies generally adopt the method of piece-based wages. However, the relevant labor laws and the social responsibility standards required by customers also include minimum wages and overtime wages. Therefore, workers The calculation of wages requires multiple considerations and overall planning.
Before adopting Ruixiang’s RFID technology, Nanwei Yueda, like other garment factories, used the method of cutting work tickets to calculate wages. After the worker completes a certain process of a bundle of semi-manufactured products, he cuts down the corresponding work ticket as a proof of workload statistics, and then a special person collects it on time and calculates the salary.
However, it is impossible to accurately grasp the working status and efficiency of each worker. More importantly, it is impossible to quickly and accurately grasp the production schedule, and it is time-consuming and laborious. Some workers even keep their work tickets for normal shifts in order to get more wages. It was not paid until the overtime day, which virtually increased labor costs.
With the advent of the era of global integration in the international clothing market and the increasingly fierce competition, market demand for small batches, multiple varieties, and short delivery times has become increasingly prominent. It is obvious that low-efficiency, high-cost, and labor-intensive clothing factories can no longer meet the demand. .
The RFID production management solution uses the employee card and the number card to accurately reflect the worker’s working status and production line production status to the computer system in real time, so that the manager can grasp the production schedule in time. Accurate calculation of production capacity and production cycle through data information, timely detection of production bottlenecks, and help managers optimize production management processes and improve production capacity.
In addition, the program automatically collects production data, replaces traditional work tickets, automatically calculates wages, effectively supervises workers, strengthens workers’ sense of responsibility, and makes management more standardized.
The senior administrator of Nanwei Yueda said that after applying Ruixiang’s RFID management solution, employees’ overtime expenses have been reduced by 15%, and the time spent on order follow-up and administrative management has been saved by 20%, which has directly improved overall productivity and shortened the production cycle. By 18%, all aspects of operational performance indicators have also improved by 15-25%.
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