Real-time management and control solution of garment production line based on RFID technology
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Project Background
In the early stage of my country’s reform and opening up, a large amount of cheap labor became a big driving force for attracting foreign investment, especially labor-intensive production and processing enterprises. A large number of foreign investment entered and one after another set up factories in the coastal areas of the Pearl River Delta. The clothing industry is a typical example. On behalf of, today, my country has long become the largest country in garment production. In recent years, the original advantage of cheap labor has been rapidly disappearing, workers’ wages have accelerated, and the prices of raw materials have also accelerated. However, the oversupply of the buyer’s market has made it difficult for manufacturers to pass on the increase in costs to consumers. Affected by this, production and processing profits are constantly being squeezed. In the face of huge cost pressure, how to ensure profitability and maintain the sustainable development of the enterprise? For a long time, the garment industry with relatively backward technological development has become an effective shortcut through technological changes to improve production efficiency and productivity, and reduce unit output costs.
Throughout the entire development process of the garment industry, summarize its typical production mode:
The cutting department picks, spreads, cuts and fills in the cut sheets according to the production plan;
Enter and print the binding sheet according to the cut sheet, which records the attributes of the piece, such as style number, size, color, batch, cutting bed number, and process number, binding sheet number and number of pieces;
After cutting, tie up the multiple layers of garment pieces in the same part according to the rules of size, cloth layer, color, etc., and tie the tie sheets to each bundle of garment pieces;
The sewing workshop goes to the cutting department to receive the bundled pieces, and bundle pieces of the same bundle number together, and then deliver the corresponding pieces to the corresponding workstations according to the production process;
After receiving the pieces, the workers at the work station perform the required procedures. After the operation is completed, they sign the job number on the stub, and cut out a small piece of paper called Fei Zai on the stub to calculate the piece wages. Proof of
The tie-up worker collects the semi-finished products completed in the previous process, bundles it with other parts of the same tie number again, and manually transfers it to the next process;
Repeat the above two steps until all processes are completed, and the finished product is packaged and put into storage.
From the above entire production process, it is not difficult to find that the entire process flow is connected in series, which guarantees the orderly progress of the entire production:
The same tie number on the tie list indicates that it is a piece of the same dress, which ensures that a piece of clothing will not be produced with different tie number pieces, and there will be no cross-color, cross-code, and cross-cut phenomenon;
The process number marked on the binding sheet ensures that the production process is carried out in order;
The labeling of its attributes such as batch number and cutting bed number also facilitates film matching and production tracking;
The employee’s signature on the bill is the basis of work and the proof of salary calculation, and the second is to facilitate quality tracking;
The indication of attributes such as quantity and style number on the bundle is also the basis for the production report statistics and production plan deployment;
demand analysis
After years of development, my country’s garment industry has formed a single-stream production model that is compatible with the garment industry with a relatively backward level of information technology. It is simple to operate, easy to learn and easy to use. However, under the pressure faced by the garment industry today, the original single management model has been difficult to meet the requirements of efficient production, and the support of electronic information technology now also provides the possibility to improve this backward production management model. Compared with the current mature RFID radio frequency identification technology, it is not difficult for us to discover the areas that need to be improved as shown by the original bundle management model:
Real-time production information uses paper bundles as the carrier, and transfers production information through the circulation of bundles. It is manually summarized through the workshop every day after get off work. It takes a long time to form a production report, so the production management department cannot accurately and in real time. Control of the complete production schedule, unable to grasp the entire production status at any time, and unable to accurately grasp the performance of production capacity, which affects the later production planning and lack of decision support for order negotiation.
In the current remuneration system for workers in the garment industry, the vast majority of workers are paid by piece. The workload is calculated by manually counting the worker’s signature record on the stub or the workmanship cut by the worker, and then calculating the workload with the corresponding worker. The price and the correlation coefficient are multiplied together to get the actual salary of each person. Such a salary statistics program requires a lot of manpower and time. The second is that manual statistics are more or less biased due to unclear or missing credentials or human error, which often causes wage disputes. In addition, Feizi is easy to circulate, and poor management will result in overpayment of part of the salary.
In general, the traditional production management mode of single-order production requires manual statistics of various production data. Production data cannot be collected in real time, and manual data collection is prone to errors, low efficiency, and high cost.
solution
In view of the areas that need to be improved highlighted by the traditional bundled production management model, Zhitao Software, based on its years of research and practical experience in the informatization of the clothing industry, proposed a real-time control of the clothing industry production line based on RFID radio frequency identification technology. Smart solutions. Utilizing the characteristics and advantages of RFID technology, through the use of RFID electronic tags, station machine readers and other RFID-related equipment and the cooperation of the production line management ERP system, intelligently identify the operation of each production process, so as to realize the real-time intelligence of production data Collection, real-time statistical analysis, real-time monitoring and management of the entire production process, including the execution and completion of orders, tracking and control of production progress, timely detection and regulation of production bottlenecks in the assembly line, traceability and control of production quality, automatic and instant calculation of worker wages, etc. Through the analysis of the accumulated production data, one is to provide an objective basis for the price of labor and to determine the price coefficient; the other is to provide a basis for the production plan of the order to achieve intelligent production scheduling; the third is to provide a basis for the process and technology to continuously improve The level of workers. In order to continuously improve production efficiency.
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