Application of RFID technology in printing production management system
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Application of RFID in printing production management
Shangji Electronics has revolutionized the introduction of RFID into the production management of the printing industry, and provides a complete set of solutions for the factory through real-time collection of worker production information and work efficiency. To help managers obtain real-time production data from the system platform, they can learn about production progress, optimize production schedules, and understand comprehensive information about employee performance, equipment status, and the number of products in progress anytime and anywhere. Various analysis data from different angles, so that managers can make objective decisions and dig deeper into more meaningful data, so as to improve the production efficiency and management decision-making ability of printing enterprises.
1. The status and characteristics of the printing industry
According to information from the State Press and Publication Administration: At present, there are 101,948 printing companies in the country with 5 million employees, and the total output value of the printing industry reached 57.62 billion yuan, accounting for about 2.5% of the GDP. “The printing industry, known as the’sunrise industry’, has extremely attractive development prospects.
Compared with other industries, the printing industry has its own characteristics. For example, the production method is special, and the production must be organized according to the work order. The printed products can only be exclusive to a certain customer and cannot be replaced or processed; there are many types of products, no matter how large or small the order is, it must be treated separately, and the workload of scheduling and accounting is large. ;Customers have high personalization requirements and high timeliness of product requirements. If the products cannot be delivered on time, the product may be scrapped and cause huge losses to the enterprise; therefore, in addition to advanced printing equipment and phototypesetting software, production scheduling is particularly important.
Real-time control of production site conditions is also an important basis for production scheduling and one of the key points for the manufacturing industry to enhance its competitiveness. However, without proper tools, it often becomes a problem for enterprises. Even with manual barcode reading work orders (or RunCARD, TRAVELCARD) used by most companies, it is time-consuming, and the accuracy and real-time issues have caused production visualization to be delayed. Shangji Electronics has revolutionized the introduction of RFID into the production management of the printing industry, which is the best tool for process management at the manufacturing site.
Two, system realization principle
Shangji’s RFID printing production management system uses radio frequency identification technology (RFID) and wireless network technology. One of the characteristics of RFID is to transmit information quickly and in real time. Through the characteristics of rapid and real-time reading of RFID, it can make the manufacturing process on site. The status is presented to managers with extreme accuracy and speed, helping managers to understand the production schedule, optimize production schedules, understand employee performance, equipment status, and work-in-process comprehensive information anytime and anywhere. A variety of analysis data from different angles, so that managers can make objective decisions and dig deeper into more meaningful data, thereby improving the production efficiency and management decision-making capabilities of printing enterprises.
System realization principle
Replace paper work orders with RFID tags, or attach RFID to work orders;
Each worker is equipped with an employee card that is shared with the attendance, meal, and access control;
Set up RFID readers in each production process;
Workers first insert their own work card during production, and then insert the material card on the work order to start work. The system starts to collect data. After completing a work order, they change the material card of the next work order without manual recording;
The system automatically records which work orders each worker is doing during which time period, the time-consuming of each work order, and where it is going to process on-site information;
Employees can check their production records throughout the day through the self-service card swiping terminal.
Three, system characteristics
3.1 Plan information flow management based on intelligent production scheduling to ensure accurate matching and on-time delivery;
3.1 Logistics management centered on material requirements and inventory management to ensure resource optimization and effective cost control
3.3 Completely solve the problems of printing production scheduling and work order scheduling;
3.4 Comprehensively solve the cumbersome management problems of the printing production process;
3.5 Difficulties in the management of printing quality throughout the process;
3.6 Use a simple method to solve the complicated printing piece rate calculation problem.
4. Actual results
1. Save labor and labor cost;
2. Reduce the error rate, at least reduce the error loss by 5%;
3. Improve production efficiency; the average finished product processing efficiency has increased by more than 30% compared with the same period; the highest finished product processing efficiency has exceeded 100% compared with the same period;
4. The key problems solved by the system
4. 1 Low accuracy and unreliability caused by manual data collection. Production companies in Guangdong and even southern China generally use manual or more traditional electronic systems to collect production and related data. A few large companies that use ERP systems actually rely on data that will inevitably produce errors, omissions and other inaccuracy. The application of RFID technology in the manufacturing process can reduce human participation as much as possible and realize automated data collection, thereby solving the problems of low accuracy and unreliable data caused by manual data collection.
4.2 The problem of out-of-synchronization of existing system data update. It is difficult for the computer systems used by existing manufacturing enterprises to collect timely data. For example, the most advanced bar code system also requires corresponding trained employees to use bar code guns and other equipment to scan related goods, but the scanned data is often not updated in the system in real time. If the barcode system is not adopted, the relevant data will be manually recorded in the form, and will be entered into the computer system at a fixed time each day. Relevant practices have caused the data in the system to be out of sync with the actual production-related data. As a result, excellent production methods, such as JIT production mode, cannot be realized due to the asynchronous system data. The advantage of RFID technology lies in automation and long-distance data collection. The corresponding monitoring equipment can automatically detect the tag data within the coverage area, so it helps to solve the problem of unsynchronized system data update;
4.3 The repeated entry of data in each link causes waste of time, manpower and cost, and increases the possibility of data errors and omissions. Most of the manufacturing enterprises in Guangdong and even southern China have not adopted the world’s advanced production management model, and most of their businesses are actually doing their own business. Raw material data is collected in the raw material supplier’s factory, product data is collected in the processing and assembly factory, and cargo data is collected in the logistics supplier’s warehouse. According to the principle of supply chain, most of the above data can be shared with each other and collected in advance. At that time, due to the inaccuracy and unreliability of data caused by traditional data collection methods, it was difficult to implement the principles of the supply chain. On the premise of solving the accuracy of data collection, RFID technology helps to link the problem of repeated data entry in each link of the supply chain. This saves a lot of manpower, material resources and time spent in data collection, and realizes the transformation of traditional manufacturing enterprises to modern manufacturing enterprises through the application of RFID technology.
Shenzhen Shangji Electronics Co., Ltd. Miss Wen 18627879710 QQ:327649063
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