Keqiao ZigBee Wireless Card Reader—Management of Production Process in Apparel ERP Industry
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1. Analysis of the status quo of the clothing production industry
1.1 The status quo of informatization construction in the clothing production industry
China is one of the world’s largest textile and clothing production countries. It has concentrated a large number of low-end and medium-end clothing suppliers in the world. There are as many as 3,000 registered clothing companies in Huizhou City, plus Dongguan, Shenzhen, Foshan, Zhongshan, There are tens of thousands of garment enterprises in Guangzhou and other garment enterprises, and the number of domestic workers engaged in garment production is even greater. Compared with other industries, the clothing production industry has unique features, such as large-scale, small-batch, multiple styles, short product cycles, strong seasonality, etc.; at the same time, as the Chinese economy enters the buyer’s market from the seller’s market, the clothing production industry The competitive pressure is unprecedented. Therefore, how to control costs, order production based on sales, and make scientific forecasts are issues that the managers of garment manufacturers attach great importance to. In this field, the informatization construction of large and small clothing manufacturers is uneven. At present, the utilization rate of electronic work tickets is less than 0.5%. There are mainly three methods for statistical work tickets:
1. Manual calculation
That is, the workers record the products, quantities, and processes they produce in a notebook, and the notebooks are collectively summarized when calculating wages at the end of the month, and there are specialized personnel to make statistics. This statistical method requires that all jobs require workers to manually count the numbers, and then specialized personnel calculate the wages. There are still many small-scale (about 100 workers) processing companies still using this method, and this method can only be used In small-scale manufacturers, otherwise the workload has risen geometrically.
2. Manual statistics
That is: the worker’s work ticket (Philippines) is printed on a fixed piece of paper in the pattern of a seal. Each time the clothes are tied, there is a large Philippine ticket, and then each process has a small sheet. When the workers produce a certain process, they use scissors to The Xiaofei of the corresponding process is cut down and used as a proof of the quantity of products produced by him, and then unified to the computer (or manually), and the total quantity is counted to calculate the salary according to the labor price.
3. Barcode calculation
Namely: With the help of computers and printers, each process of Dafei on a bundle of goods is printed by barcode (divided into: dot matrix printer, laser printer, professional barcode printer, etc., each printer has different costs). Workers are in production In the process, according to their own production conditions, use scissors to cut off their own process barcodes, which are used as production certificates, and then unifiedly summarized, and a dedicated person scans the workers’ barcodes (work tickets) into the computer system.
1.2 Research on the problems caused by traditional counting, paper and bar code recording modes
The clothing production industry can continue to use manual counting, manual counting of paper and bar codes, etc., but why do we recommend changing to electronic? This is because the electronic Philippine can solve the two major series of problems caused by the past stamping and semi-automatic ticket production. The management is difficult and the cost is high. These problems are reflected in the following points:
1. In the past, manual calculations, paper and barcodes brought management difficulties
A. Some workers are busy rushing to produce, while others are sitting and waiting for nothing to do? This is because the efficiency of the workers is different, which can easily cause uneven division of labor in the team;
B. Once it is found that the quantity of certain processes is abnormal, how do you know which worker and which day the problem occurred?
C. The accuracy of traditional manual data collection is not high. The barcode system is used, and the labor efficiency is low. For example, the worker must manually cut a barcode every time he does a process and keep it properly; perhaps it takes only 30 seconds for the worker to do a process , And it takes 10 seconds to manually cut a bar code, the actual working time utilization rate is not high;
D. Managers in the clothing production industry must have a deep impression. Take barcodes as an example. Once the barcodes are not clearly printed or have folding marks, the barcode guns are difficult to identify, and statisticians often fail to identify them. Barcode Philip has a headache;
E. Collecting information is to have a dedicated statistician enter the information after the next day, so that the current work status cannot be understood in real time, and it is impossible to track it in real time. It is difficult for the management to arrange work according to the work status. If there is a problem in a certain process of the work process , If you want to exclude it, you must wait until the next day. This will undoubtedly increase the management difficulty and cause economic losses.
2. In the past, manual calculations, paper and barcodes have caused labor costs to rise
A. Philippine ticket statistics sometimes need to be specially arranged for a team of personnel. Based on a 1000-person factory, the salary of three statistical employees is about RMB 4,500, and a year of RMB 54,000, which is a large labor cost;
B. The consumption of bills paper and printers every month is a huge and invisible account. If a production workshop produces 10,000 pieces of clothes per day, each piece of clothing needs to consume 5 barcodes and 50,000 barcodes per day. The total consumption of barcodes per month is 1.5 million. If printing a piece of barcode paper and printing supplies costs 0.03 yuan, a month is ￥45,000, and a year is ￥540,000;
C. The wages of automatically resigned employees are collected by other employees, and the loss of income caused by backward management methods such as logarithmic time-consuming caused by manual entry cannot be estimated.
2. What is the RFID real-time production line of the clothing industry
RFID real-time production line is the general trend of the garment industry, and its development prospects are very broad. The RFID real-time production line project of the clothing industry is also called the RFID electronic work ticket for the clothing industry, usually referred to as the electronic work ticket. It is a platform that uses wireless workstations to cooperate with ERP software companies in the clothing production industry. It integrates the advanced management experience of hundreds of domestic clothing and footwear industries and the current smart card reading and writing technology, data acquisition technology and other concentrated high-tech projects. reflect. It introduces the application of smart cards to the clothing industry, using RFID electronic work tickets instead of traditional paper bar code work tickets to truly collect production data in real time. Solve the problems of slow collection speed, backward statistical methods, and high statistical costs in the past.
RFID real-time production line workflow:
1) When cutting and bundling, it is equipped with a smart material card to replace the barcode work ticket or the first sign;
2) Install a station machine (card reader) on each sewing car or on a post that requires piece counting;
3) When an employee is working, the employee swipes each bundle of materials to be produced on the station machine, instead of manually cutting the work ticket, the station machine automatically collects it in real time.
All the card swiping data on the workstation machine is collected by the system in real time at a speed of 115.2Kb per second. With these raw data, ERP software can easily count which work orders employees are doing during which time periods and how long each process takes. Realize real-time monitoring and intelligent distribution of workshops, helping companies obtain real-time production progress, employee performance, time for each package of clothing, and quality information, and make real-time on-site scheduling, balance on-site production bottlenecks, and improve production processes.
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