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1. Project background
With the development trend of economic globalization, traditional intensive processing and manufacturing industries, such as clothing, electronics, food, tobacco, automobile and other industries, have higher and higher single product manufacturing costs and lower and lower processing profits. Profit margins, optimization of corporate management processes, and information transformation to improve production efficiency have become one of the effective methods.
In the production process of traditional manufacturing enterprises, most of the production modes are based on the one-piece production mode. The biggest disadvantage of this production line mode is that there is usually a large backlog of semi-manufactured products in certain bottleneck processes. If the process is complicated and With more production links, this phenomenon will become more serious. These problems have weakened the management staff’s ability to predict, control and respond to the production cycle, and it has become increasingly difficult to cope with the market requirements of large orders and short delivery times.
2. System introduction
The production line management system based on RFID technology has become one of the effective solutions to the above problems. By adopting RFID technology, the system can automatically collect production data and equipment status data, provide production managers with “real-time data” of all process links in the production line, and can Combining the process characteristics of each process equipment and related process and quality index parameters, conduct online monitoring and analysis of production information such as process parameters and equipment operating parameters of important links in production, helping enterprises to realize the measurement of semi-finished and finished processes in the production process , The automation and information integration of warehousing and exit management, so as to achieve automatic real-time tracking of production operations, can effectively supervise each production post, and supervise the stability of product quality and the implementation rate of process parameters.
The RFID production line management system uses electronic work tickets instead of traditional paper work tickets, uses an RFID electronic tag for each single product on the production line, and installs an RFID reader at each station. When a worker completes a job, the system automatically sends the information of the workpiece directly to the computer system through the RFID collection device, and the system automatically completes piece rate calculation and various production statistics, providing a complete solution for the enterprise.
Third, the overall system architecture
The RFID production line management system is an MES project that uses RFID card swiping to complete process flow and data collection to solve the problem of production process control. At the same time, based on the successful experience of implementing ERP and MES systems in the past, it completes the process from procurement, inventory, sales to finance The whole set of accounting information system planning realizes the organic integration of sales, purchase, inventory, production, finance, quality, cost, equipment, technology, and personnel management, and realizes the company’s comprehensive informationization and paperlessness.
Four, system process design
Take a complete clothing production line as an example, design the rfid node process management as follows:
1) Each roll of cloth is assigned an RFID electronic label with a unique ID number, and the cutting department picks, spreads, and cuts according to the production plan. At the same time, the RFID collection terminal is used to record at the three nodes of picking, spreading and cutting. The basic information of the picker, picking time, picking product name, cloth specification, spreader name, cutter name and other basic information are entered into the electronic bed sheet and uploaded to the back-end database on the computer side;
2) After cutting, bundle the multi-layer garment pieces of the same part according to the rules of size, cloth layer, color, etc., and then assign a new RFID electronic label binding sheet for each binding, and associate the electronic label binding sheet with the corresponding cutting sheet. On the sheet sheet, enter the attributes of each piece of clothing at the same time, such as style number, size, color, batch, cutting bed number, and information such as process number, note number and number of pieces; the function of the electronic label tie sheet is to mark the piece of clothing Attributes, cutting batches, indicating the processing procedures that need to be performed for the bundle of garments and the number of products in this batch, as well as recording the workload information of each station;
3) The sewing workshop goes to the cutting department to receive the bundled pieces, bundles the pieces of the same bundle number together according to the production process, and delivers them to the corresponding station by hand; the workers completely rely on the information on the bundle Carry out production operations to ensure that each piece of clothing is sewn from pieces of the same attribute in accordance with the planned process. Each station is equipped with an RFID reader, which is responsible for collecting basic information such as station number, working hours, worker information, process, etc., and uploading it to the computer back-end system;
4) The worker at the station receives the garment piece and performs the operation of the specified procedure. After the operation is completed, the RFID reader is used to collect the electronic tag binding ID number and associate it with the work number, and upload it to the back-end system for calculating piece wages. certificate;
5) The tie-up worker collects the semi-finished products completed in the previous process, bundles them with other parts of the same tie number, and manually transfers to the next process;
6) Repeat steps 4 and 5 until all procedures are completed. The finished product is packaged and the label information is collected by the RFID collector and stored in the warehouse.
Five, system characteristics
1) Strong controllability, can accurately plan the allowable range of data collection;
2) The content of the label can be read and written, and can be reused, saving costs;
3) Provide automated means for information systems to obtain real-time data;
4) Realize fine production and on-time production;
5) Optimize the production process, improve production and management efficiency;
6) Cost saving;
7) Analysis of production bottlenecks and alarms;
8) High real-time, safe and stable;
9) Realize product quality traceability.
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