Automatic dynamic management system scheme for wireless RFID production line
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Preface
China is a major textile and other producer in the world. According to customs data, in 2008, the growth rate of my country’s textile and apparel exports continued to slow down. According to my country’s customs data, my country’s textile and apparel exports totaled US$189.6 billion in 2008, an increase of 7.98% year-on-year. From the data point of view, textile exports still maintain a continuous growth trend. But at the same time, we should also see that new changes have also taken place in the economic situation at home and abroad. Uncertainties in the external economy have increased. The RMB has appreciated by more than 6%, the export tax rebate rate has been reduced by 2 percentage points, the loan interest rate has been increased by 14.48%, and the pressure on labor costs has continued to rise. The country’s tight macro policies have also brought industry development. Pressure. Faced with such a situation, we should see that global science and technology are changing with each passing day, and backwardness will be eliminated, and there will be no benefits without innovation. The current changes in the domestic and international situation should be seen as a new period for the overall development of China’s industry. We should seize the opportunity and actively accelerate industrial upgrading through innovation, and not miss this opportunity at a critical juncture of historical development.
Automated dynamic management system process
The RFID production line automated real-time dynamic management solution is to use radio frequency identification technology (RFID) and wireless communication technology (zigbee) to creatively design a new generation of industrial products by introducing RFID electronic industrial technology: use ID cards to replace paper products, Use a card reader to replace the manpower to enter the Philippines, and then collect the data in real time through the system, and add to the analysis to provide real-time and accurate analysis reports to the management. Through these real-time data reports, the management can understand the production dynamics of the front line in real time and discover the production. Bottlenecks, optimize the process to shorten the production cycle. Real-time dynamic exchange of worker production information and monitoring of work efficiency through the back-end management center provide a complete set of solutions for the factory. Help managers obtain real-time production data from the system platform, and can understand comprehensive information about production progress, employee performance, parking space status, and the number of products in progress anytime and anywhere. At the same time, the dynamic management system establishes a connection channel for managers, company executives and front-line workers in the workshop. The production progress of each worker can be directly fed back to the manager, real-time statistics of worker piece rate, evaluation of worker performance, and multiple analysis data from different perspectives. , So that managers can make objective decisions and dig deeper into more meaningful data. Thereby improving the production efficiency and management decision-making ability of garment enterprises.
System realization principle
>> When the materials of each process are cut and flew out, they are equipped with a smart card;
>> Each worker is equipped with a work card;
>> Install a wireless work ticket/work card reader (RFID controller) on each locomotive;
>> Workers first read their own work cards during processing. After each process is completed, the smart card that has been affixed will be sensed once on the wireless work ticket/work card reader, and the system will exchange data with the management background in real time to complete one Change the material card of the next work order after the work order;
>> The system automatically records which work orders each worker is doing during which time and how long it takes;
>> Use the worker card reader to automatically complete the quantity acquisition of the subsequent work orders in the trapping process on the production line;
>> Employees can check their production records throughout the day through the self-service card swiping terminal;
>> The system counts and calculates the production progress of each group, each station, and each process in real time, and provides the best and accurate production data for the manager’s worker deployment, improves work efficiency, and reduces the waste of human resources.
1. Direct benefits
>> Management standardization: improve productivity and transparency of the production line, save wages, take responsibility to individuals, reduce defective products, optimize production management processes, and reduce the accumulation of products in the production line;
>> Operation automation: automatic collection of production data, less input of labor, automatic calculation of salaries, complete elimination of work tickets, eliminate transfer of work tickets, and save costs;
>> Information digitization: real-time monitoring of production bottlenecks, accurate calculation of production capacity and life cycle, and automatic generation of various intelligent analysis reports;
>> Efficient work: Through the accurate real-time production progress data provided by the system, the waste of manpower is reduced.
2. Leap in value of the system
After applying the RFID production line real-time dynamic management solution, in addition to the above-mentioned benefits for the enterprise, it can also bring an additional leap in value for the enterprise:
Process-improved perpetual motion machine
>> At present, there are very few domestic manufacturing factories that really have IE departments, even if there are departments with a few people. The designed production process action cannot be verified on a large scale;
>> After applying this solution, it is equivalent to including all front-line workers into the IE department. The system can always find the fastest workers among the many workers engaged in the same process operation, and it is easy for them Even small improvements and advancements have been discovered and promoted;
>> Turn individual small improvements into improvements for all employees. And this discovery process will always be repeated. So it is truly a perpetual motion machine for process improvement;
>> If the production efficiency can be increased by 1% on the original basis every day, what will be the result after 70 days? The efficiency is 200% of 70 days ago!
Be fair
>> Many of the process unit prices set by IE have not been implemented through a lot of verification, resulting in some processes that are relatively simple and valuable, and some are troublesome and worthless. On-site division of labor will cause artificial unfair distribution;
>> Applying this solution can accurately know whether the unit price of each process man-hour estimated by IE is reasonable, and how to modify it to be fair.Balanced production, real-time scheduling investment return analysis
◎ It can save labor cost by 5-8%
◎ Reduce production loss by 10-20%
◎ Increase productivity by 10-30%
◎ Reduce the inventory of products in the production line
◎ Improve and better service to customers
Timeliness comparison
This timeliness is often a big issue that has been overlooked. In the past, enterprises’ understanding of wage statistics was often at the level of purely calculating wages, so as long as the workers hand in the wages, the wages will be calculated smoothly at the end of the month and everything will be fine. Therefore, the Philippines is usually paid once every two or three days. The most diligent and hardest thing is to pay the Philippines once every night. However, the employees who enter the Philippines will not work overtime to enter the Philippines, so the calculation is more than once a day. As a result, the production dynamics are seriously inaccurate, and the power of all analysis reports generated on this basis will be greatly reduced. The delivery date will be delayed, and the strategic deployment of the management will be affected.
Take a typical customer as an example. There are 3,000 lathe workers, with an average monthly salary of RMB 2,000, and the total monthly wages of lathe workers are about 4.5 million. After the application of the RFID production management system, the average salary is saved by 5%, which is 225,000, and consumables are saved 3 Ten thousand yuan per month, the staff’s salary is 80 thousand yuan per year, and the production efficiency has increased by 8%. Assuming a 10% gross profit margin, the customer can earn an additional 3 million yuan in profit this year.
◎ 8% labor cost can be saved
◎ Reduce production loss by 10%
◎ Shorten the production cycle by 18%
◎ Increase productivity by 30%
◎ Improve employee customer satisfaction
Industry Solutions
Project background of garment industry production line
At present, large and medium-sized garment factories in China (with more than 1,000 sewing machines) generally adopt a non-automatic manual assembly line production method, and the production process is basically the same. The typical production process is as follows:
1. The cutting department picks, spreads, cuts and fills in the cut sheets according to the production plan;
2. After cutting, bundle the multi-layer garment pieces of the same part according to the rules of size, cloth layer, color, etc., and bind the binding sheet entered and printed out according to the cut sheet on each bundle of garment pieces, and the binding sheet records the The attributes of garment pieces, such as style number, size, color, batch, cutting bed number, and information such as process number, bundle number and number of pieces;
3. The sewing workshop goes to the cutting department to pick up the bundled pieces, bundle the pieces of the same bundle number together according to the production process, and deliver them to the corresponding workstations by hand;
4. After the worker at the station receives the garment piece, perform the operation of the specified process. After the operation is completed, sign the job number on the stub of the tie, and cut off a piece of the tie (called the fly) as the calculation piece. Proof of salary;
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 again, and manually transfers to the next process;
6. Repeat steps 4 and 5 until all procedures are completed, and the finished product is packaged and put into storage.
The function of the binding sheet is to indicate the attributes of the garment pieces, the batch to be cut, indicate the processing procedures that need to be performed for the garment piece and the number of products in this batch, and record the workload information of each station. After the fabric is cut, the workers rely solely on the information on the binding sheet to perform production operations to ensure that each piece of clothing is sewn from the same attributes in accordance with the planned process. At the same time, the workers who perform each process also have to settle the piece-rate wages with the reserved slips. Therefore, the tie-up is a key tool that links all production operations together.
demand analysis
1. The management of production through the use of tie sheets is a set of current solutions summed up by the garment industry after years of exploration. This set of solutions is simple and practical, and matches the overall informatization level of the garment industry. However, as customers’ demands for rapid response production and visualized production supervision continue to increase, the way of managing orders shows a lot of room for improvement.
2. The monitoring of production progress only stays on paper, and the workshop is summarized once every day after get off work. In this way, the production management department cannot accurately grasp the production progress in real time. The result of this state is that the information of the company’s decision makers is lagging, so the production status cannot be immediately understood, and the production capacity cannot be accurately grasped, which affects the later production planning and arrangement and lacks decision support for order negotiation.
3. 99% of workers’ remuneration system in the garment industry is piece rate. The current wage calculation method adopted by the garment industry is to calculate the workload by counting the worker’s signature record on the stub and the worker’s cut-off slips, and then multiplying it by the unit wage to get the wages of each worker. This work requires a lot of manpower, is error-prone, and often causes disputes. In addition, since it is impossible to record the time spent by workers in each process in real time, the approval of the labor cost for each process is very subjective, and it is easy to cause disagreements. Therefore, almost every day in garment factories, workers have objections to wages.
4. The content of the bundle cannot be flexibly customized. Because the current binding slips are all printed on the printed binding slips, different product information can only be printed on the binding slips in the same format. Sometimes the cutting workers need to write by hand to supplement the content.
The main reason for the above problems is that the paper bundles cannot meet the requirements of real-time and accurate production information collection, sorting and analysis. Manually recording the completion status of the main processes and counting the completion time of each process with a stopwatch is the only production information collection method in the garment factory at present. The tie-up is the main clue to track the production progress of each batch of products. Through this information collection method, only lagging information feedback can be obtained, and production plans and business decisions made based on this will inevitably have errors. Therefore, the real-time production information collection method is the key to improving production efficiency, optimizing management methods and obtaining decision support for garment manufacturers.
solution
A non-contact smart card is used instead of a paper-based bundle. Each time a processing is completed, the card is swiped on the workstation to record personnel and time records. The smart card electronic binding is passed along with the garment pieces to each process; a data collection terminal is arranged at each station, and all the reading heads are connected with the main server to form a system network. When the garment pieces are transferred to the specified process for processing, the worker scans the electronic binding on the data collection terminal, and the system records the start time of the processing process. After the processing is completed, the worker presses the end button to notify the system that the process has been completed. Each employee is equipped with a smart card work card, and register with the work card when entering a station, so that all operations performed by the station are associated with the employee’s work card, so as to realize automatic statistics of workload, automatic settlement of wages, and Trace quality responsibility. In view of the particularity of the industry, we designed a solution specifically for the industry, using wireless communication, an ultra-simple installation mode, which solves the traditional RS485 installation speed, high technical requirements for installers, difficult maintenance, and low real-time performance. Series of questions.
Use RS232 to connect a wireless transceiver on the client computer. The transceiver establishes a wireless network with the card reader through ZigBee wireless communication technology, and the wireless communication distance is 80 meters. A wireless repeater can be installed beyond this distance. The communication distance between the wireless transceiver and the repeater is 250 meters, the wireless repeater to the card reader is 80 meters, the wireless repeater and the wireless repeater are 250 meters, and the same route is at most Connect 5 relays. The credit card device for this industry also has the following functions:
1. Able to upload punch-in data and manually entered data. When receiving data, it is also possible to distinguish whether it is punch-in data or manually entered data. The uploaded data will not take effect until the system returns the information. If the punch-in data is not confirmed, it is still saved. , Then the check-in record will be read the next time the card is re-read. Normally, if the data is not confirmed, it will be invalid next time;
2. The card reader can receive prompt messages in Chinese from the system in time;
3. After the card reader is turned on, it can automatically display the number, job number, process, and status: offline (online), support 4-line Chinese display;
4. If the number entered on the keyboard is wrong, you can clear it and enter it again, click OK and then submit;
5. Able to control whether the keyboard can input through commands;
6. Able to send normal and abnormal voice prompts through commands.
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