Application case of barcode equipment in electrical industry assembly line
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In the stage where there is no barcode application, each product in each production line must manually record the processes and parts required to generate this product. There is a record form for each product in each production line. After each process is completed, fill in the component number and the worker’s job number, and the operation is completed. In this process, the workload is very large and complex, and it cannot immediately reflect the flow of products on the production line.
After the barcode technology is adopted, the order number, part type, and product quantity number are first formed into barcodes, and the barcodes are printed and pasted on the production line of product parts and assemblies. In this way, it is very convenient to obtain the production process of a product order on a certain production line and the required materials and parts. After the product is completed on the production line, the quality inspector of the production line will scan the product barcode and production line code number after passing the inspection, and scan the worker’s barcode in the sequence of the process (it can be determined once and unchanged). For unqualified products sent for repair, the cause of the failure (process location) will be determined by the repair. The main advantages of barcode application in production management are as follows:
The production process of the product can be reflected immediately and effectively on the production line, saving the labor of manual tracking.
The production process of products (orders) can be displayed on the computer, and the bottleneck in production can be found; the production data can be quickly counted and inquired to provide the basis for production scheduling and order scheduling.
For unqualified products in the inspection, it can record the problems caused by workers or parts, and provide practical analysis reports.
The following case describes how electrical appliance companies use barcodes to monitor production in the production process.
There are four main goals to be achieved by the system:
Quality tracking: can track the model (main board, power supply or other main accessories) of the whole machine and 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.
Real-time dynamic tracking of production: The actual production situation can be known from the computer at any time.
Customer Tracking: The customer’s name, address and shipment quantity can be obtained at any time from the computer.
Report function: Provide various management reports for management review.
formulate specific plans
Barcode automatic identification technology has the characteristics of fast input speed, high accuracy, low cost and easy operation. In automated assembly lines and in each process, barcodes are used to label major components with barcodes. After being collected and decoded by the barcode reader, the barcode information is input into the database of the computer server. Every machine and major component will have a unique barcode. No matter where the machine is sent, there will be a record. If there is a problem, just 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
This system can contain four main databases: system design library, user library, PCB library and whole machine library. The information that the barcode label must contain: 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 used on the PCB board, the whole machine, the packing box and the warranty card respectively.
For example, when designing the barcode format of the PCB board, consider the model, production site, production date, production team, production line, batch number and serial number.
The main work of this part is each code, which can reflect the various conditions of the product in a timely and complete manner, and can achieve the uniqueness of each component.
The main functions of the bar code management system: system management, PCB board production management, final assembly production management, warehouse management and other functions. System Management System parameter design, system database changes, operator management and password management.
PCB board production management Printing barcodes: According to the requirements, in addition to printing the barcodes of the PCB board, the barcodes of other related accessories are automatically printed at the same time. For the PCB board, the barcode is printed in two copies, one is attached to the PCB board; the other is randomly used for the 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 statistics and form reports as needed.
Production management: At each key point of the production line, configure barcode reading equipment. Workers scan their job number on the production line first, and record the start time at the station. Scan the barcode of the PCB board, record the work start time, scan the number of the accessories to be installed on this station, and enter the production data; after the completion, enter the completion time, and transfer the product to the next station until the assembly of the product is completed. After the product is assembled, according to the number of the PCB board, print the barcode of the whole machine and the packaging box, and send the packaged product to the warehouse.
Print barcodes: Print barcodes on the whole machine, boxes and warranty cards. Barcode Scanning: Scan the whole machine to form a finished product library. Statistical analysis: query and statistics and form reports as needed. Warehouse management: At the beginning of warehousing, use fixed scanning equipment to scan the finished product packaging barcode of the warehousing assembly line, record the warehousing time, form the warehousing registration of finished products, and increase the inventory in the warehouse. When out of the warehouse, scan the barcode of the packaging box of the whole machine according to the out-of-warehouse plan to verify whether the product data of the out-of-warehouse is consistent with the plan. Complete the outbound operation.
Using the barcode of the whole machine and the handheld barcode scanning terminal, the inventory work of the warehouse can also be carried out.
Using barcodes as storage location and shelf coding can realize automatic warehouse kinetic energy, and use barcode positioning to automatically enter and exit the warehouse. Inbound and outbound management: generate inbound and outbound orders, and form inbound and outbound reports by scanning inbound and outbound products.
Statistical analysis: query and statistics and form reports as needed. Other functions: Quality tracking: query the model (main board, other main accessories) and production data of the main PCB boards used by the barcode of the whole machine. 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 barcode composition can be set by the user. Warehouse Center: Warehouse management inside the factory and remote management of the warehouse outside the factory.
After-sale service: Warranty card and maintenance record management.
The manual operation in the past has become less and less suitable for 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 are made by many people after manual statistics, which is labor-intensive and repetitive and cumbersome. After using the barcode tracking system, the above 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 production conditions in a timely, accurate and comprehensive manner, so as to take necessary and effective measures to ensure that production can be The scheduled program is proceeding as normal. After the production line adopts the bar code 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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