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Facing increasingly fierce market competition, many manufacturing companies have implemented ERP/MRP systems to help companies improve their management level and enhance their ability to respond to competition and changes. However, the upper-level production planning management is increasingly affected by the market, and enterprises obviously feel that the plan cannot keep up with the changes. Faced with customers’ demanding requirements for delivery time, more product modifications, and continuous adjustment of orders, corporate decision makers realize that the formulation of plans depends on the market and the actual execution status of operations, and cannot be completely based on materials. And inventory returns to control production. At the same time, ERP/MRP software is mainly for resource planning. These systems can usually handle things that happened before yesterday (for historical analysis), and can also predict and process events that will happen tomorrow, but they often leave behind the events that are happening today. Irregular gaps. Therefore, the on-site management of production has always been in a state of black box operation, which has been unable to meet the complex and ever-changing competitive needs of today. Therefore, how to make this black box operation transparent, not only can find out all the problems that affect product quality and cost, improve the real-time and flexibility of the plan, but also improve the operating efficiency of the production line has become a concern of all enterprises.
The production management barcode/RFID solution emphasizes the management of the production site, and the application of barcode/RFID technology realizes the automated and rapid collection of a large number of real-time data generated during the production operation, and timely processing of real-time events. At the same time, it maintains two-way communication with the planning layer (ERP/MRP), receives corresponding data from the planning layer and feeds back processing results and production instructions. The production management barcode/RFID solution effectively solves the problems of manufacturing companies in the management of production site operations, makes it easier for companies to manage production data, and realizes effective management of production processes, product quality traceability, and subsequent inventory and sales tracking.
The role of barcode/RFID in production management:
Why should bar code/RFID be introduced in production management?
1) A large amount of real-time useful data will be generated at the production operation site, and these production data will play an important role in the rapid decision-making of enterprises.
2) The data on the production site is mainly collected by the operators on the production site. Since the operators on the production site are both producing and collecting data, if the original manual collection method is used, not only the input speed is slow, but the error rate will be high.
3) The data of the production site is scattered in many different process links, and barcode/RFID is needed as a link to connect the information of each production link, so as to track the whole process of the product from the beginning of production to the finished product.
How to introduce barcode/RFID into production management?
1) Use a process card printed with a barcode/RFID symbol.
According to the production order or production plan, use a barcode/RFID printer to print out a process card before each single product or batch/order product starts production; the process card corresponds to a single product or a batch of products one-to-one , And during the production process, as the product circulates in each link of the production line, in each production link, the production site operator uses a barcode/RFID reader or a handheld terminal to scan the barcode/RFID on the process card to obtain the previous The production data of the production link, and the relevant information of this operation link is recorded on the process card, until the product is formed and packaged.
2) Use barcode/RFID symbols to indicate the items to be collected and print them on the label.
For example: each management object can be identified with a unique identity serial number, and the serial number barcode/RFID label can be printed out and pasted on the management object that needs to be tracked. At the same time, some auxiliary data objects (such as procedures, operators, production lines, production shifts, etc.) can be identified by barcode/RFID to further realize automatic data collection.
3) Use a handheld data terminal with barcode/RFID scanning function for production management.
For applications where it is impossible to arrange computers on the production line, and do not need to collect data in real time, and the data in each link is unrelated or not closely related, a handheld data terminal can be used to first disperse the collection, and then focus on batch processing. At this time, the production site workers are equipped with a handheld data terminal with barcode/RFID scanning function for on-site data collection. At the same time, relevant information can be queried on site, and relevant data in the system will be downloaded to the handheld terminal before that.
4) Upload and synchronization of data.
The data collected on site is uploaded to the production management system in real time via the wireless network, and the data in the system is automatically updated. At the same time, the updated data in the system can also be downloaded to the handheld terminal for inquiries and calls on site. Features and advantages of the production management barcode/RFID solution:
Pay attention to the management and control of the production site operation process, featuring the application of barcode/RFID technology.
The application of advanced bar code/RFID technology to objectively identify the data that needs to be collected in the production site operations, to achieve the automated and rapid collection of a large number of real-time data generated during the production operations.
In the production management process, a barcode/RFID identification is assigned to each data management object in the enterprise:
1) After the barcode/RFID reading device has swiped the barcode/RFID identification, the barcode/RFID will be interpreted to accurately identify each data management object.
2) The detailed information of the identified data management object is stored and transferred to the computer to accurately complete the collection of the data.
3) The automatic error correction and real-time alarm function fundamentally eliminates the inevitable errors in manual input in the past, and ensures the complete authenticity and reliability of the first-hand data in the basic data statistics.
Perfect integration with the planning layer to enhance the application value of the ERP/MRP system
On the basis of solving the bottleneck problem of data collection and input in the original ERP/MRP system, it maintains two-way communication with the planning layer (ERP/MRP), receives corresponding data from the planning layer and feeds back processing results and production instructions, thereby improving ERP/ The application value of the MRP system.
Tailor-made personalized solutions, to a large extent, to meet the production process of the enterprise
On the basis of the basic application framework, the production management barcode/RFID has an in-depth understanding of the enterprise’s production operation process, tailored personalized solutions for the enterprise, and met the enterprise’s operation process and management needs to a large extent.
Benefit evaluation:
1) Reduce human error input, realize seamless connection between production data and management business, reduce the workload of management personnel, and reduce the time for each work supervisor to process documents by 75%-90%.
2) There is no need to extract work team members to record production data, and all workers can fully engage in production.
3) Increase the accuracy of production data collection, make the production plan more accurate, and complete orders faster.
4) Improve the company’s management level and lay a good foundation for further exerting the application effects of the original ERP/MRP system.
5) Record the time spent by the staff to complete the work, grasp the work efficiency of the staff, and enhance the management of the staff.
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